Light emitting mirror bezel

ABSTRACT

A multi-function rearview device for use with a vehicle includes a housing configured to be attached to the vehicle and to be moveable relative to the vehicle, a rearview element including at least one of a reflective element, a camera and a display element, a bezel formed at an outer portion of the multi-function rearview device surrounding the rearview element, with the rearview element being attached to at least one of the bezel and the housing, one or more light assemblies providing at least one or more light function indications, including a Human Machine Interface (HMI), and at least one sensor, the sensor controlling the one or more light assemblies or the display element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/569,270, filed Sep. 12, 2019, which is a National Stage Entry ofInternational Patent Application No. PCT/EP2018/056299, filed Mar. 13,2018, which claims the benefit of priority to U.S. Provisional PatentApplication No. 62/470,658, filed Mar. 13, 2017, which is herebyincorporated by reference in its entirety for all purposes; and thisapplication is a continuation-in-part of U.S. patent application Ser.No. 16/273,664, filed Feb. 12, 2019, which is a continuation-in-part ofU.S. patent application Ser. No. 15/256,532, which claims the benefit offoreign priority to European Patent Application No. 15183748.1, filedSep. 3, 2015, each of which is hereby incorporated by reference in itsentirety for all purposes; and this application is acontinuation-in-part of U.S. patent application Ser. No. 15/256,540,filed Sep. 3, 2016, which claims the benefit of foreign priority toEuropean Patent Application No. 15183758.0, filed Sep. 3, 2015, each ofwhich is hereby incorporated by reference in its entirety for allpurposes; and this application is a continuation-in-part of U.S. patentapplication Ser. No. 16/180,857, filed Nov. 5, 2018, which is acontinuation-in-part of U.S. patent application Ser. No. 15/922,266,filed Mar. 15, 2018, which is a continuation-in-part of U.S. patentapplication Ser. No. 15/800,413, filed Nov. 1, 2017, which is acontinuation-in-part of U.S. patent application Ser. No. 15/603,751,filed May 24, 2017, which claims the benefit of foreign priority toEuropean Patent Application No. 16198759.9, filed Nov. 14, 2016, each ofwhich is hereby incorporated by reference in its entirety for allpurposes; and this application is a continuation-in-part of U.S. patentapplication Ser. No. 15/533,118, filed Jun. 5, 2017, which is a nationalstage entry of International Patent Application No. PCT/IB2015/059419,filed Jun. 9, 2016, which claims the benefit of foreign priority toEuropean Patent Application No. 14196582, filed Dec. 5, 2014, as well asEuropean Patent Application No. 15162850, filed Apr. 8, 2015, each ofwhich is hereby incorporated by reference in its entirety for allpurposes; and is a continuation-in-part of U.S. patent application Ser.No. 15/607,894, filed May 30, 2017, which is a continuation-in-part ofU.S. patent application Ser. No. 15/000,754, filed Jan. 19, 2016 and nowissued as U.S. Pat. No. 9,796,333, which is a continuation-in-part ofU.S. patent application Ser. No. 14/022,896, filed Sep. 10, 2013, whichclaims the benefit of foreign priority to German Patent Application No.102012108480.7, filed Sep. 11, 2012, each of which is herebyincorporated by reference in its entirety for all purposes; and is acontinuation-in-part of U.S. patent application Ser. No. 15/439,188,filed Feb. 22, 2017, which is a continuation-in-part of U.S. patentapplication Ser. No. 14/936,024, filed Nov. 9, 2015 and now issued asU.S. Pat. No. 9,656,601, which is a continuation-in-part of U.S. patentapplication Ser. No. 14/374,376, filed Jul. 24, 2014 and now issued asU.S. Pat. No. 9,181,616, which is a national stage entry ofInternational Patent Application No. PCT/AU2013/000047, filed Jan. 24,2013, which claims the benefit of foreign priority to Australian PatentApplication No. 2012900267, filed Jan. 24, 2012, each of which is herebyincorporated by reference in its entirety for all purposes.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The following description relates to vehicle rearview devices, Forexample, such rearview devices may include a bezel which can beilluminated to provide different functions to the driver or otherpersons viewing the bezel.

2. Related Art

Exterior rearview devices of vehicles incorporating light sources arewell known in the state of the art. Typically, a flashing directionindicator is installed for increased safety and enhanced design, as forexample described in U.S. Pat. No. 7,600,905 or EP Patent No. 2 340 967.

Also, warning indicators and other light sources have been integratedinto the housing, bezel and behind the rearview element to function as aturn signal, break signal or blind spot indicator. Such light sourcesare described in EP Patent No. 2 151 350, EP Patent No. 2 463 152, EPPatent No. 2 463 153, U.S. Pat. Nos. 7,674,025, 8,164,482. Warningindicators using optical fibers have also been used in an externalrearview device in U.S. Pat. No. 7,954,985. Additionally exteriorrearview devices can be equipped with video displays and display devicesand have also been used as indicators, for example in U.S. Pat. Nos.7,777,611 and 7,581,859.

Lighting systems illuminating the ground and the area around the door toincrease the security of the vehicle occupants have been incorporatedinto external rearview devices and are well known, such as described byU.S. Pat. No. 6,149,287.

An interior rearview device is known from EP Patent No. 2 106 970 toprovide ambient light originating from behind the reflective part of therearview element. This configuration provides a bezel-less design tominimize the needed space and fulfill certain design criteria forenhancing the appearance to the driver.

For all these purposes, different type of light sources and guides havebeen identified to meet the demand for high brightness, low powerconsumption and the ease and flexibility of installing them, some ofwhich are described in EP Patent No. 3 138 734 and EP Patent No. 3 061587.

Also, mirror reflective elements with heater pad including electricallyconductive traces are described by United States Patent ApplicationPublication No. 2016/0221505. United States Patent ApplicationPublication No. 2016/0221505 describes a mirror reflective elementassembly for an exterior rearview mirror assembly for a vehicle includesa reflective element and a heater pad. The heater pad includes a heaterpad substrate having a plurality of electrically conductive tracesestablished thereat. The heater pad substrate is disposed at a rearsurface of the reflective element. The electrically conductive tracesmay include (i) a heating trace that, (ii) first and secondelectro-optic control traces and/or (iii) accessory control traces.

U.S. Patent Application No. 2017327167 describes a method formanufacturing an automotive mirror, in particular a side mirror,includes forming a printed circuit board as flexible printed circuitboard with n+1 branches, nεN, providing n modules each including atleast one electronic element, and connecting up to n of said branches toone module each and connecting one branch to cables or a cable harnessto be connected to a power supply and/or a control unit outside themirror.

U.S. Pat. No. 8,550,675 B2 teaches an outside mirror lighting assemblywhich includes a housing and a first glass panel where one or more lightemitting devices are positioned at an edge of the first glass panel.Light rays from the at least one light emitting device propagate withinthe glass panel for illumining its outer periphery. Words, logos, orother indicia may be also be illuminated by direct or indirect lightemitted into an etched area of the glass. The mirror assembly supplies asoft illuminated glow around the outer periphery and/or the indicia forproving a unique and pleasing appearance to the user.

US 2008/112176 A1 describes that an exterior rearview mirror has amirror head, which is provided with a mirror glass and with at least oneilluminant, which radiates light through at least one light permeablesection to the exterior. Furthermore, the exterior rearview mirror has amirror base. In order to provide the exterior rearview mirror, so thatthe light function is performed in an optimum manner through the simpleprovision of the mirror, at least part of the housing of the mirror headand/or of the mirror base is comprised of at least two plastic layers,having different light permeability. In the light permeable section, theplastic layer with the lower light permeability is missing, or it onlyhas such thickness, that the light emitted by the illuminant radiates tothe exterior with sufficient light intensity. The plastic layer withhigher light permeability can be used as a light pane for the illuminantdisposed behind it. The plastic layer with lower light permeability canbe provided to provide the transparent section with a proper color.

DE 20 2016 102 024 U1 discloses a warning indicator system for avehicle, comprising a warning indicator arranged to surround areflective element carried in a rearview mirror assembly of the vehicle.

US 2005/276058 A1 teaches an exterior rearview mirror for vehicles, inparticular motor vehicles. The exterior rearview mirror has a mirrorhousing with a mirror glass, which is mounted on a mirror glass supportand is encompassed by a frame. The exterior rearview mirror is providedwith signal lamps, area lights, and indicator lights that are situatedin the mirror housing or in the mirror base. In order to permit asimple, inexpensive installation of a lamp into the exterior rearviewmirror so that it does not take up much space, at least one lamp of abuilt-in light is accommodated in the frame. The lamp, which is fastenedto the frame in a non-detachable way, can be accommodated in the framein a simple, space-saving way and held there securely. The exteriorrearview mirror is particularly suited for motor vehicles.

EP 0 967 118 A2 discloses an exterior mirror assembly for a vehicle thatincludes a signal light that provides an advanced notification system toapproaching vehicles that the driver of the vehicle intends to turn ormake a lane change. The exterior mirror assembly includes a housing witha reflective element and a positioning device for adjusting the positionof the reflective element in the housing, and at least one signal lightpositioned in the housing. The signal light includes a light source anda light conduiting member which is adapted to project a pattern of lightfrom the housing and yet restrict light from extending into the vehicleso that a driver seated in the vehicle does not directly observe thepattern of light. The light source may be provided by a light pipe whichis optically coupled to a remote light source located, for example, inthe vehicle. The pattern of light may extend at least rearwardly andlaterally from the vehicle. In one form, the light conduiting memberincludes a light input surface on one end and at least one lightemitting surface for directing light outwardly from the housing of theexterior mirror assembly. In another form, the exterior mirror assemblyincludes a powerfold mirror system which incorporates a security lightwhich directs light in a first light pattern when mirror assembly is inits normal use position and a second pattern when the mirror assembly isin its folded position.

US 2008/106389 A1 describes a mirror reflective element sub-assembly foran exterior rearview mirror assembly of a vehicle, and the sub-assemblyincludes a mirror reflective element and a video display element. Thevideo display element is disposed behind the mirror reflective elementso that images displayed by the video display element are viewablethrough the mirror reflective element when the video display element isactivated. The video display element is configured to display imagesthat are readily viewable by the driver of the host vehicle and notreadily viewable by drivers of other vehicles in the lane adjacent tothe host vehicle.

EP 2 151 350 A1 teaches a rear view mirror including a reflectiveelement in a cavity of a mirror housing with a mirror head and a mirrorbase. An indicator light for indicating situation information to avehicle driver is installed, wherein the indicator light includes lightsources and an optical element that allows the light to shine through.The indicator light has a split printed circuit board to support atleast two light source elements and a light guide wherein the lightemitted from the light sources is coupled into the end faces of thelight guide.

US 2010/177523 A1 describes a rearview mirror assembly for use on avehicle, which comprises a housing configured to be coupled to thevehicle, a mirror coupled within the housing, and a first optical fibercoupled to the housing and visible from the exterior thereof forproviding a warning that indicates that the vehicle is turning, braking,and the like.

US 2007/019426 A1 discloses an interior rearview mirror assembly for avehicle, which includes a reflective element, a frame portion around aperimeter of the reflective element, and one or more user inputs orbuttons movably mounted to the frame portion. At least one bezel segmentis positioned partially around the perimeter of the reflective elementand frame portion and defines a space or gap along the frame portionbetween opposed and spaced apart ends of the bezel segment or segments.The input or button is mountable to the frame portion at the space andis movable by a user to engage and actuate an electronic switch withinthe mirror assembly.

EP 1 598 237 A1 teaches a device having a mirror housing with at leastone mirror glass mounted on a mirror glass support and enclosed by aframe. At least one light source of a built-in light is mounted in theframe. The light source is overlapped by an upper part of the frame.

Rearview devices are located at a highly visible position with respectto the vehicle driver. State-of-the-art external rearview devices have atypically black or colored bezel surrounding the rearview element.Typically, the rearview element is not attached to the bezel but to anattachment plate to allow for the adjustment of the rearview element tothe needs of the vehicle driver. When adjusting the rearview element tothe needs of the vehicle driver, the actuators only move the rearviewelement. Therefore, additional space between the bezel/housing and therearview element is needed and nothing can be positioned there whichleads to lost installation space. Typically, the actuator may adjust therearview element within an angle of at least 8 to 12 degrees. Thisadditionally leads to electronics and other components placed behind therearview element to be exposed to environmental conditions.

In addition, rearview devices typically incorporate a number of separateand individual modules for providing different functions such as lightmodules, heating pads, among other functions. This results in a mirrorassembly with many components and which has a high manufacturing cost.

As a result, there is a need for a rearview mirror assembly with animproved space utilization to allow for additional functions andelements to be integrated and to provide additional functions for thedriver of the vehicle and other persons.

Therefore, it is advantageous to utilize the highly visible position ofthe rearview device to provide additional and important information tothe driver. Especially when using a sealed rearview device which isintegrally formed out of its components and moving the whole rearviewdevice during adjustment of the rearview device to the driver, theadditional space previously needed to adjust the rearview element is nolonger needed to be kept free and can be used for the installation ofadditional components and functions into the rear view device directlybehind the rearview element and/or attached to the bezel.

SUMMARY

A multi-function rearview device for use with a vehicle includes arearview element including at least one of a reflective element, acamera, and a display element, a bezel formed at an outer portion of themulti-function rearview device surrounding the rearview element, wherethe rearview element is attached to at least one of the bezel and ahousing which is configured to be attached to the vehicle and to bemoveable relative to the vehicle.

The bezel may be made of a plastic substrate which is at least one ofcolored, surface finished, transparent, and coated.

The coating of the bezel substrate may be at least one of a decorativecoating, an advanced surface technology (AST) surface coating, and aspectrally controlling system.

The bezel may be formed or molded from a polymeric substrate.

The bezel may be transparent and may include a chromium-based coating,making the one or more light assemblies beneath the bezel hidden untillit.

The chromium-based coating may be an alloy of chromium and a dopantmaterial, the dopant material being selected from hexagonallyclose-packed transition metals, the alloy having a crystal structure ofa primary body-centered cubic phase in coexistence with a secondaryomega hexagonally close-packed phase.

The one or more light assemblies may provide at least one or more lightfunction indications including direction indicator, approach light,strong braking signal, emergency braking signal, logo light, puddlelight, Human Machine Interface (HMI), Blind Spot Indicator (BSI),charging indicator status, vehicle mode, sports mode, economy mode,autonomous drive mode, sleep mode, vehicle locked, vehicle stolen,warning signals, temperature or weather indicator, traffic light signal,fuel status, emergency indications for emergency vehicles including apolice vehicle, doctor vehicle, ambulance, or traffic maintenance,vehicle communication, handshake, connection indicator, and hazardlights.

The one or more light assemblies may each include at least one of aprinted circuit board, a light emitting diode, an integrated lens, aself-charging illuminating material; a flexible circuit board; a bulb;and a lamp.

The light assembly may be configured to direct light to differentpositions of the bezel.

The light assembly may be configured to direct a light with differentcharacteristics to different positions of the bezel for providingdifferent light function indications.

The plurality of light assemblies may be configured to direct light withdifferent characteristics to different positions of the bezel forproviding different light function indications.

The different light characteristics may be determined by at least one ofthe light color, the light intensity and the light pulse length.

The different positions of the bezel may include at least a position onthe bezel above the rearview element, a position on the bezel below therearview element, a position on the bezel facing the vehicle, and aposition on the bezel not facing the vehicle.

The plurality of light assemblies may include four light assemblies, afirst light assembly positioned within the interior space of the bezelabove the rearview device, a second light assembly positioned within theinterior space of the bezel below the rearview device, a third lightassembly positioned within the interior space of the bezel at a positionon the bezel facing the vehicle, and a fourth light assembly positionedwithin the interior space of the bezel at a position not facing thevehicle.

The one or more light assemblies may be placed directly on a plasticpart of the bezel without using a printed circuit board, or by using asurface mount, over mold, conductive material, or printed material.

At least one of a conductor track, the electronic means and the one ormore light assemblies may be directly applied to the bezel by at leastone of injection molding (MID), by a conductive foil (IML) and laserdirect structuring (LDS).

The one or more light assemblies may include an LED holder with anintegrated connector which can be clipped into the interior space of thebezel.

The one or more light assemblies may include at least one light sourceunit with at least one wire, but not including a printed circuit board,a housing unit supporting the light source unit and being provided withmeans suited for at least one of holding and connecting, and sealingmeans.

The one or more light assemblies may include a light source including atleast one of an LED light, a light tape, a printed lighting, an opticallight guide, a lamp, an illuminating charging material, a charging cell,a solar powered cell, or a battery.

The multi-function device may include the one or more light assemblies,where the one or more light assemblies are configured to direct aplurality of different color lights to an entire surface of the bezel sothat the entire bezel can have one color at a time, and are configuredto provide a plurality of different color lights to different zones ofthe bezel so that different zones of the bezel can have different colorsat a time.

The housing, the reflective element, and the bezel may be integrallyformed so that the multi-function device is sealed from an outsideenvironment to protect against dust, water, or humidity.

The multi-function device may further include a light diffuserpositioned within the interior space of the bezel.

The multi-function rearview device may be functionally connected to anactuator, and the actuator may be positioned outside the housing.

The multi-function rearview device may be functionally connected to theactuator by self-docking or direct contact.

The actuator may move the multi-function device entirely including thehousing, and not only the rearview element.

The actuator may be configured for at least one of a rotational movementand a translatory movement.

The multi-function device may further include a foot suited to be fixedto the vehicle and relative to which the housing with the bezel ismoveable.

The foot may provide at least one spherical seat for the housing.

The housing may include an upper part and a lower part, and the bezelmay be attached to both parts.

The bezel may be secured, glued, removably attached, or clipped to thehousing.

The bezel may be attached together with at least one of the one or morelight assemblies and the electronic means to the housing.

The actuator may determine the light output of the one or more lightassemblies.

The actuator may determine the light output of the one or more lightassemblies using a LIN or CAN connectivity.

The multi-function device may further include a connection to a controlunit of the vehicle to control at least one of the one or more lightassemblies, the display element, an actuator, a camera controller, or acleaning device.

The multi-function device may further include at least one sensorwherein the output of the sensor controls at least one of the one ormore light assemblies, the display and an actuator.

The sensor may be a camera.

The multi-function device may further include at least one of a heaterand a wiper for the rearview element.

The electronic means may be connected to at least one of the one or morelight assemblies, the display element, an actuator, a sensor, a camera,a heater and a wiper.

The electronic means and the bezel may form a unit.

The multi-function device may further include auto dimming elements.

The multi-function device may further include a light sensor forcontrolling multiple light intensities or light brightness.

The one or more light assemblies may provide at least one or more lightfunction indications including a side marker indication or a parkinglight indication.

The multi-function device may further include a flexible circuit whichincludes the one or more light elements, the one or more light elementsbeing directly attached to the flexible circuit.

The flexible circuit may further include a single connector controllingunit configured to control the one or more light elements and to receivean external connector.

The flexible circuit may further include an integrated heating padconfigured to heat the rearview element.

The flexible circuit may further include an integrated temperaturesensor.

The flexible circuit may further include at least one of an integratedWi-Fi or Bluetooth communication unit and an antenna.

The flexible circuit may further include an integrated heating padconfigured to heat the rearview element and which bends around a slotformed in the bezel.\

The bezel may include a light receiving portion which is configured toreceive a light for functioning as an indicator, in particular a sideturn indicator.

The one or more light elements may be at least two light elements whichare configured to project different colored lights for providingdifferent functions.

The one or more light elements may be at least four light elements whichare configured to project different colored lights for providingdifferent functions.

The different functions provided may include direction indicator,approach light, strong braking signal, emergency braking signal, logolight, puddle light, Human Machine Interface (HMI), Blind Spot Indicator(BSI), charging indicator status, vehicle mode, sports mode, economymode, autonomous drive mode, sleep mode, vehicle locked, vehicle stolen,warning signals, temperature or weather indicator, traffic light signal,fuel status, emergency indications for emergency vehicles including apolice vehicle, doctor vehicle, ambulance, or traffic maintenance,vehicle communication, handshake, connection indicator, hazard lights,side marker indication and/or a parking light indication.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description,will be better understood when read in conjunction with the appendeddrawings. For the purpose of illustration, there is shown in thedrawings certain embodiments of the present disclosure. It should beunderstood, however, that the invention is not limited to the precisearrangements and instrumentalities shown. The accompanying drawings,which are incorporated in and constitute a part of this specification,illustrate an implementation of systems and apparatuses consistent withthe present invention and, together with the description, serve toexplain advantages and principles consistent with the invention.

FIG. 1 is a diagram illustrating a perspective view of an example of arearview device.

FIG. 2 is a diagram illustrating another perspective view of therearview device with a line A-A.

FIG. 3 is a diagram illustrating a sectional view of the rearview devicealong the line A-A illustrated in FIG. 2.

FIG. 4 is a diagram illustrating an example of a light assembly.

FIG. 5 is a diagram illustrating a perspective view of the rearviewdevice and two examples of a detail of the rearview device.

FIG. 6 is a diagram illustrating an example of an integrated flexiblecircuit including one or more lighting elements.

FIG. 7 is a diagram illustrating a perspective view of an example of arearview device including the integrated flexible circuit of FIG. 6.

FIG. 8 is a diagram illustrating a perspective view of another exampleof a rearview device including another integrated flexible circuit.

DETAILED DESCRIPTION

Before explaining at least one example of the invention in detail, it isto be understood that the invention is not limited in its application tothe details of construction and to the arrangements of the componentsset forth in the following description or illustrated in the drawings.The Figures and written description are provided to teach any personskilled in the art to make and use the inventions for which patentprotection is sought. The invention is capable of other embodiments andof being practiced and carried out in various ways. Those skilled in theart will appreciate that not all features of a commercial embodiment areshown for the sake of clarity and understanding. Persons of skill in theart will also appreciate that the development of an actual commercialembodiment incorporating aspects of the present inventions will requirenumerous implementation-specific decisions to achieve the developer'sultimate goal for the commercial embodiment. While these efforts may becomplex and time-consuming, these efforts nevertheless would be aroutine undertaking for those of skill in the art having the benefit ofthis disclosure.

In addition, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of description and should not beregarded as limiting. For example, the use of a singular term, such as,“a” is not intended as limiting of the number of items. Also the use ofrelational terms, such as but not limited to, “top,” “bottom,” “left,”“right,” “upper,” “lower,” “down,” “up,” “side,” “corner,” are used inthe description for clarity in specific reference to the Figures and arenot intended to limit the scope of the invention or the appended claims.Further, it should be understood that any one of the features of theinvention may be used separately or in combination with other features.Other systems, methods, features, and advantages of the invention willbe or become apparent to one with skill in the art upon examination ofthe Figures and the detailed description. It is intended that all suchadditional systems, methods, features, and advantages be included withinthis description, be within the scope of the present invention, and beprotected by the accompanying claims.

FIG. 1 is a diagram illustrating a perspective view of an example of arearview device 100. Referring to FIG. 1, the rearview device 100includes a housing 110, a rearview element 120 and a bezel 130. Thebezel 130 can be subdivided into multiple different zones 130A, 130B,130C, 130D. As an example, four (4) different positions or zones 130A,130B, 130C, 130D are shown. These different positions 130A, 130B, 130C,130D provide different functions or a combination of differentfunctions, such as indicators to the driver and other persons.

The multi-function rearview device bezel 130 with four, or any number ofseparate zones 130A, 130B, 130C, 130D, each with one or more or acombination of the following functions (single colored or multiplecolored light source): transparent coating; AST coating; chargingindicator; logo lamp; approach light side turn indicator; HMI/BLIS;vehicle mode (sport/economy); autonomous driving mode; sleep mode;vehicle locked; vehicle stolen; warning signals; temperature/weatherindicator; traffic light signal; strong/emergency braking signal; fuelstatus; among other functions.

The light in the different positions 130A, 130B, 130C, 130D can havedifferent characteristics, such as color, intensity and pulse length butcan also be used to provide the same light at the same time as toilluminate all or part of the bezel 130. A foot may be connected to therearview device 100.

FIG. 2 shows an example of the rearview device 100 highlighting the lineA-A which is used for the cross-sectional view of FIG. 3.

FIG. 3 is a diagram illustrating a sectional view of the rearview device100 along the line A-A illustrated in FIG. 2. The rearview element 120of this example is a glass substrate with a reflective coating on theinner surface. A lighting assembly in the form of an LED light strip 140is attached to a diffuser 150. The diffuser 150 is attached to the bezel130. The bezel 130 is a multi-functional exterior glass bezel 130 withan integrated transparent and chrome-based coating as to function as acosmetic mirror bezel molding. A painted part 115 of the housing 110 isshown, which can be scalp painted.

FIG. 4 is a diagram illustrating an example of a lighting assembly 200.The lighting assembly 200 of this example includes a connector 210, aPCB board 220, an LED 230, one or more lenses 240 and at least onefilter 250. The light assembly may be placed in an external housing 260.

FIG. 5 is a diagram illustrating a perspective view of the rearviewdevice 100 and two examples of a detail of the rearview device 100.

Referring to FIG. 5 and the detail of the rearview device 100, a lightassembly 200 according to FIG. 4 may be placed inside the rearviewdevice 100. An external connector 210A is shown to control and providepower to the light assembly 200. The rearview device 100 includes themulti-functional external mirror glass bezel 130 and is shown oncewithout and once with an integrated lens 240.

According to the aforementioned examples, this description provides amulti-functional rearview device 100 for use with a vehicle including amulti function rearview element 120, a housing 110, and a bezel 130. Thehousing 110 may be configured to be attached to the vehicle and to bemoveable relative to the vehicle when attached thereto. The rearviewelement 120 may include at least one of a reflective element and displayelement and is attached to at least one of the housing 110 and the bezel130.

The housing 110 can be made out of a single part or may include an upperand a lower part where the bezel 130 is attached to both parts.

The bezel 130 may be formed at an outer portion of the housing 110surrounding the rearview element 120 and may include an interior spaceformed within the bezel 130 and at least one of one or more lightassemblies 200 and one or more electronic means positioned within theinterior space of the bezel 130. The bezel 130 may be formed as oneintegral portion or may be formed from multiple segments 130A, 130B,130C, 130D such as two segments including an upper and lower portion,four segments 130A, 130B, 130C, 130D including four sides, or any numberof segments.

The bezel 130 can be formed or molded from any type of glass. Glass ishere used in the sense of a non-crystalline amorphous solid showing aglass transition when heated towards the liquid state. Especially suitedare polymeric substrates not only due to their light weight, costefficiency and durability. The bezel may be interchangeable andremovable with a standard non-lit bezel so that a non-lit bezel may beremoved and a bezel providing lighting and indications is substituted inits place. The non-lit bezel may be opaque, clear, transparent, ortranslucent. Similarly the lit bezel may be opaque, clear, transparent,or translucent.

The bezel 130 can be molded to include recesses at the interior face tohouse at least one or more light assemblies 200, one or more electronicmeans and other internal structures of the rearview device 100.

The bezel 130 may include a colored, surface finished, transparent orcoated surface and it or the space beneath it may be used to house atleast one of light electronics and at least parts of other functionssuch as a heater or a wiper incorporated within the rearview device.

The bezel 130 can also be configured to be secured, glued, clipped, orremovably attached in any way to the housing 110.

The transparent material or the surface coating can be used tocommunicate light from the one or more light assemblies 200 inside therearview device 100 to the outside, for example to the driver of thevehicle or to any other person or sensor watching the rearview device100. For example, a transparent bezel 130 including a chromium-basedcoating may be used, thus making the light assemblies 200 beneath thebezel 130 hidden from the outside viewer until lit.

The chromium-based coating can be an alloy of chromium and a dopantmaterial, the dopant material being selected from hexagonallyclose-packed transition metals, the alloy having a crystal structure ofa primary body-centered cubic phase in coexistence with a secondaryomega hexagonally close-packed phase.

The multi-function device or bezel 130 may include only one lightassembly 200 or multiple light assemblies 200. The one light assembly200 or the multiple light assemblies 200 can be configured to directlight to different positions of the bezel 130 and can provide differentlight characteristics for different positions of the bezel 130 toprovide different light function indications. These differentcharacteristics can include at least one of the light color, the lightintensity and the light pulse length.

The coating can obstruct different light applications. To be able toshape the light according to different needs, part of the bezel surfacecan be spared from the coating or the coating can be removed afterwardsto form special shapes. A lens 240 may be molded directly into this orother parts or added afterwards. This allows for example to project acompany logo to the ground when no coating is applied or when thecoating is removed from the lower part of the bezel 130.

The different positions of the bezel 130 may include at least a position130A on the bezel 130 above the rearview element 120, a position 130C onthe bezel 130 below the rearview element 120, a position 130B on thebezel 130 facing the vehicle, and a position 130D on the bezel 130 notfacing the vehicle. Within each position a single light assembly 200 canbe positioned within the interior space of the bezel 130. For example, afirst light subassembly 200 can be positioned within the interior spaceof the bezel above the rearview device 120, a second light assembly 200positioned within the interior space of the bezel 130 below the rearviewdevice 120, a third light assembly 200 positioned within the interiorspace of the bezel 130 at a position on the bezel 130 facing thevehicle, and a fourth light assembly 200 positioned within the interiorspace of the bezel 130 at a position not facing the vehicle.

Alternatively, the bezel 130 can be subdivided into numerous positionsto provide multiple different light functions and multiple differentlight subassemblies 200 can be positioned within the interior space ofthe bezel at numerous positions.

The one or more light assemblies 200 can include a light source 230having at least one of an LED light, a light tape, a printed lighting,an optical light guide, or a lamp.

The one or more light assemblies 200 or the electronic means can bedirectly placed on a plastic part or on the bezel 130 without using aprinted circuit board 220. One or more conductor tracks can connectdifferent parts of the one or more lighting assemblies and theelectronic means and connect also to other electrical systems inside andoutside of the rearview device 100. Alternatively, the plastic part orthe bezel 130 can be molded around the conductor tracks, the one or morelight assemblies 200 or the electronic means. The at least one conductortrack, the electronic means and the one or more light assemblies 200 canbe directly applied to the plastic parts or the bezel 130 by one or moreof injection molding (MID), a conductive foil (IML), and laser directstructuring (LDS).

The one or more light assemblies 200 can also include an LED holder withan integrated connector 210 which can be clipped into the interior spaceof the bezel 130.

The one or more light assemblies 200 can also include at least one lightsource unit 230 with at least one wire, no printed circuit board, ahousing unit supporting the light source unit and designed with meanssuited for at least one of holding and connecting as well as sealingmeans to protect and seal the LED from the environment.

The one or more light assemblies 200 can be configured to direct aplurality of different color lights to an entire surface of the bezel130 so that the entire bezel can have one color at a time, and can beconfigured to provide a plurality of different color lights to differentzones of the bezel so that different zones of the bezel can havedifferent colors at a time.

In an example, the light assemblies may include a printed circuit board(PCB) 220, a light emitting diode (LED) 230 and an integrated lens 240.

The light stemming from the one or more light assemblies 200 of thedifferent embodiments can be used to provide at least one or more lightfunction indications at different positions including directionindicator, blind spot indicator, approach light, strong braking signal,emergency braking signal, logo light, puddle light, human machineinterface, charging indicator status, vehicle mode, sports mode, economymode, autonomous drive mode, sleep mode, vehicle locked, vehicle stolen,warning signals, temperature or weather indicator, traffic light signaland fuel status.

In certain examples, at least some of the light may be directed at theground or to the direction of other persons or sensors outside thevehicle to communicate information. The rearview device may furtherinclude a light diffuser positioned within the interior space of thebezel. The housing 110, the reflective element 120, and the bezel 130 ofthe rearview device 100 may be integrally formed so that themulti-function device 100 is sealed from an outside environment.

The multi-function rearview device 100 can be functionally connected toan actuator, whereby the actuator is positioned outside the housing.This can allow the actuator to move the multi-function device 100entirely including the housing 110, and not only the rearview element120. The actuator can be configured to perform one or more differenttypes of movements, among them being rotational movements andtranslatory movements.

The actuator can also be configured to determine the light output of theone or more light assemblies 200. The rearview device 100 may include afoot suited to be fixed to the vehicle and relative to which the housing110 with the bezel 130 is moveable.

In an example, the foot provides at least one spherical seat for thehousing 110.

In another example, the bezel 130 is attached together with at least oneof the one or more light assemblies 200 and the electronic means to thehousing 110

The rearview device 100 may include a connection to a control unit ofthe vehicle to control at least one of the one or more light assemblies200, the rearview element 120 and an actuator

Additionally, the rearview device 100 can include at least one sensor.The output of the sensor can be used to control at least one of the oneor more light assemblies 200, the reflective element 120, the actuatoror any other functions and systems, such as a heater and a wiper.

The rearview device 100 can include a connection to a control unit ofthe vehicle to control at least one of the one or more light assemblies200, the rearview element 120 and an actuator. This sensor can be forexample a camera.

The rearview device 100 can further include additional functions andsystem such as a heater or a wiper. The electronic means can beconfigured to control and connect one or more of the one or more lightassemblies 200, the display element 120, an actuator, a sensor, acamera, a heater and a wiper. The electronic means can also form a unittogether with the bezel 130.

FIG. 6 is a diagram illustrating an example of an integrated flexiblecircuit 600 including one or more lighting elements 610.

Referring to FIG. 6, light and signal modules and sensors that areprovided in exterior door mirrors are typically provided as individualmodule assemblies and connected using conventional wire harnesses toindividual rigid PCBs. In a preferred example, the rearview device mayinclude lighting, sensors and heating functions which are allincorporated into one flexible printed circuit/ribbon circuit 600 whichis secured using adhesive to the a surface of the rearview device suchas to a glass surface to operate as a heat sink. The flexible circuit600 may provide single point electrical connection and self-dockingconnection to all peripheral mirror functions and mounting surfaces forLED lights and electronic components while also providing flexibility toposition the lights and sensors in the correct positions. Accordingly,these peripheral electrical functions may be integrated into the fixedglass case bezel and can be removed, assembled, or serviced in one easyoperation utilizing the rotation assembly motion of the glass carrierbezel.

In this example, the flexible circuit 600 may include one connectorcontrolling unit 620 and a flexible heater pad or ribbon circuit 630 towhich one or more lighting elements 610 are directly attached.

FIG. 7 is a diagram illustrating a perspective view of an example of arearview device including the integrated flexible circuit of FIG. 6.

Referring to FIG. 7, a rearview device 700 may include the integratedflexible circuit 600. As already described in reference to FIG. 6, theflexible circuit 600 includes one connector controlling unit 620 and aflexible heater pad or ribbon circuit 630 to which one or more lightingelements 610 are directly attached. In this example, five lighting unitsare attached and face in separate directions and may project differentcolored lights as described throughout this application. For example,first light 610 a may project a blue light, second and third lights 610b, 610 c may project a red light, fourth light 610 d may project a greenlight, and fifth light 610 e may project a yellow light, all light beingable to change colors and able to be used for different functions. Theone connector controlling unit 620 may control all function on the bezelincluding all lighting elements 610 a-e and the heating pad and atemperature sensor 640. The connector controlling unit 620 may beconfigured to receive a harness with a connector 710, and is describedpreferably as one controlling unit 620 may but more than one may beprovided.

Accordingly, the case bezel 720 of the rearview device 700 may beprovided as part of a single piece fixed glass bezel assembly withintegrated lighting and other modules. The bezel 720 may include a lightreceiving portion 740 which forms a built in Side Turn Indicator module,in this case, receiving light projected by the fifth light 610 e. Aglass reflector 750 may be provided on an opposite side of the bezel720, but it should be appreciated that the described bezel 720 andflexible circuit 600 are equally applicable for use in a cameramonitoring system (CMS).

In providing a single piece fixed glass bezel assembly 700 withintegrated flexible circuit/ribbon 600, one assembly is provided thatintegrates all peripheral electrical mirror functions into one easilyserviceable part allowing for easy customer upgrade possibilities andreducing service costs. Electronic components fixed to the flexibleribbon 600 may also provide a mirror glass defrost heater element andcould also utilize the mirror glass as a heatsink. A single pointelectrical connector 620 integrated into the flexible circuit 600 willprovide electrical connection to the vehicle and could be connectedusing a traditional electrical connector or a self-docking connectorwhen used in conjunction with the rotating bezel concept. This alsoprovides for reduced packaging space and repeatable locations/routingfor multiple features.

FIG. 8 is a diagram illustrating a perspective view of another exampleof the rearview device including another integrated flexible circuit.

Much like the rearview device 700 of FIG. 7, the rearview device 900 ofFIG. 8 includes a flexible circuit 800 with integrated lighting elements810, an electrical connector 820, and a temperature sensor 840. Theflexible circuit 800 may include an attached heater pad 830 which isformed as an appendix to the main body of the flexible circuit 800; forexample, attached by a narrower neck portion to the main body of theflexible circuit 800. This allows for the heater pad 830 to be receivedin a slot 960 formed in the bezel 920 so as to position the heater pad830 in an ideal location such as bent around the slot 960 and behind theglass reflector 950. In addition, the flexible circuit 800 may alsoinclude a communication module 850 such as a Bluetooth or Wi-Fi module,and an integrated antenna 860.

Similar to the rearview device 700, the rearview device 900 may beconfigured to receive a harness with a connector 910. The case bezel 920of the rearview device 900 may be provided as part of a single piecefixed glass bezel assembly with integrated lighting and other modules.The bezel 920 may include a light receiving portion 940 which forms abuilt in Side Turn Indicator module, in this case, receiving lightprojected by the fifth light 810. A glass reflector 950 may be providedon an opposite side of the bezel 920, but it should be appreciated thatthe described bezel 920 and flexible circuit 800 are equally applicablefor use in a camera monitoring system (CMS).

This application also relates to a light assembly, a rear view device,and a light module for a light assembly of an exterior rear view devicefor a vehicle, as described in U.S. patent application Ser. No.15/256,540, which is hereby incorporated by reference herein in itsentirety for all purposes.

A light module for a light assembly of an exterior rear view device mayinclude a light source unit with at least one wire, which is suited foran electric connection with a printed circuit board of the rear viewdevice, in particular of the light assembly. The light module furtherincludes a housing unit supporting the light source unit, and isprovided with connecting and/or holding means which are suited for theattachment to at least one part, in particular a housing part, of therear view device. The light module further includes sealing means, whichare suited for a water and dustproof connection between the light moduleand the at least one part.

It is preferred that the light source unit includes an optoelectroniccomponent electrically connected with the wire(s), a radiation surface,preferably provided by a transparent and/or translucent resin embeddingthe optoelectronic component, and an light source housing, eitherincluded by the housing unit or attached to the housing unit.

Further, preferred examples may be characterized in that the housingunit may be formed together with the light source housing and/or thesealing means, such as by hot embossing or 2-K injection molding.

The housing unit may be formed with a through hole for each wire, and/orthe housing unit may be formed with a receiving structure for the lightsource unit, and/or the housing unit may be formed with the connectingand/or holding means, such as for a plug or snap connection.

The connecting and/or holding means may include at least 2 snaps, eachsnap being provided with a stop element. In another example, 1 snap maybe used, in another example, 3 snaps may be used, and in anotherexample, 4 snaps may be used, and any number of snaps may be used.

Further, the sealing means may be placed around the perimeter of thehousing unit or may form the perimeter of the housing unit in the regionsupporting the light source unit. Additional examples may becharacterized in that one or more light source units may be supported bythe housing unit, and/or each light source unit includes an LED unitwith one or more LEDs. In another example, at least two light sourceunits are used. In another example, at least three light source unitsare used, and any number of light source units may be used.

In addition, a light assembly of an exterior rearview device may includea side turn indicator, a blind spot detection, a logo lamp, a doorhandle light and/or an approach light with at least one light module asdescribed herein.

The light assembly may include at least one printed circuit board remotefrom the light module to which the one or more wires is soldered andproviding a soldering pad pattern.

The soldering pad pattern may include at least 1 pad, preferably 2 pads,for each light module, with each pad having an area of 3 to 5 mm² and/orthe 2 pads having a distance of at least 0.5 mm or an extension of alength and/or width of at least 0.5 mm, and/or outside the pad(s) asolder resistant is provided on the printed circuit board.

An electronic circuit board unit may be connected to each light moduleand a power supply, and/or one electronic circuit board unit may beconnected to two or more light source units, in particular the lightsource units being connected in series or in parallel.

The electronic circuit board unit may include at least one drivercircuit for directly or indirectly connecting to the power supply and atleast one printed circuit board, preferably one printed circuit boardfor all light modules of a plurality of light modules or one printedcircuit board for each light module.

At least one plug connection for electronically and physicallyconnecting the printed circuit board(s) and/or the driver circuit may beprovided.

In addition, the invention may also provide an exterior rearview devicefor a vehicle, including at least one light module as described hereinand/or at least one light assembly as described herein.

The radiation surface of the light module may flush with the exteriorsurface of at least one housing part of which the light module isattached via its connecting and/or holding means. In another example,the radiation surface of the light module overlaps or underlaps with theexterior surface of the at least one housing part of which the lightmodule is attached, and a number of different overlapping, flush, orunderlapping arrangements may be used.

The light module may be provided with a plurality of advantages bymaking usage of three components in form of a light source unit, ahousing unit, and a sealing means. At first, it is to be noted that thelight source unit, which can be an LED unit, may be without a printedcircuit board such that a solderless light source holder is providedwhich reduces production costs. In addition, the housing unit not onlyholds or supports the light source unit but also is provided withconnecting and/or holding means for facilitating the attachment of thelight module in a rearview device, which also reduces production costs.Still further, due to the fact that the sealing means is provided forwater and dustproof, the lifetime of the light module within theexterior rearview device is prolonged.

It can be advantageous to form the housing unit together with a lightsource housing of the light source unit and/or the sealing means, suchas with a 2-K injection molding process to further save costs.

The light module may be connected to a remote printed circuit boardbecause it may not have its own such that a high degree of flexibilitywith respect to mounting positions within the exterior rearview devicemay be provided. Thus, a light assembly including a single printedcircuit board connected to a plurality of electronic consumer units,including light modules as described herein, may have a very simplesystem architecture with a reduced amount of parts.

The printed circuit board of the light assembly may have an improvedheat dissipation and enhanced performance due to a special soldering padpattern. For example, one light module of the invention may be connectedwith two wires to two pads of said pattern with the minimal distancebetween two pads being at least 0.5 mm and/or there being an extensionat each pad having at least one dimension of at least 0.5 mm. Stillfurther, the printed circuit board can be covered by a solder resistantoutside the soldering pads.

In case the light module is provided with several light source unitsconnected in parallel, the amount of wires to be connected to thesoldering pad pattern can be reduced compared to a separate arrangementof each light source unit.

An exterior rearview device of the invention can include one or morelight modules, in particular for providing a side turn indicator, ablind spot detection, a logo lamp, a door handle light and/or anapproach light. Each of those functions can be fulfilled by a lightmodule with all of the light modules being connected to a single circuitboard arranged remote from said light modules providing a high degree offlexibility with respect to the arrangement of the light modules withinthe exterior rearview device.

As each light module is provided with a sealing means, substantially nowater and dust can enter the interior of the exterior rearview devicewhich is necessary to guarantee a long lifetime.

This application also relates to an electronic device configured for usein a rear-view device of a motor vehicle and a rear-view deviceincluding such an electronic device, as described in U.S. patentapplication Ser. No. 15/256,532, which is hereby incorporated byreference herein in its entirety for all purposes.

An improved rear-view device for a motor vehicle which is configured foruse in a rear-view device for a motor vehicle includes at least onehousing device having at least one floor piece and a cover piecearranged or that can be arranged on the floor piece, which in the joinedstate delimits an at least almost completely closed cavity, with atleast one first retaining means of a retaining unit, through which thehousing device can be or is fixed in or on the rear-view device, andwith at least one electronic module, including at least one conductorunit and at least one contact means connected with the conductor unit,wherein on a surface of the floor piece and/or cover piece turnedtowards the cavity the conductor unit is arranged, having at least onecarrier and at least one conductor track applied directly to thecarrier, the contact means extending through the cover piece and/orthrough the floor piece with at least one protruding contact section isaccessible externally, the at least one carrier of the at least oneconductor unit is formed at least in sections by a functional surface ofthe floor piece and/or the cover piece adjacent to the cavity and turnedtowards the cavity, and the cover piece and/or floor piece with the atleast one first retaining means of the retaining unit form or forms acommon component.

Additional preferred examples of the electronic devices are alsodescribed.

In that at least one carrier of a conductor unit is formed at least insections by a functional surface of the floor piece and/or the coverpiece, the electronic device has fewer components and can be compactlydesigned. This also reduces the assembly effort.

Apart from the conductor tracks the conductor unit can include furtherelectronic components such as integrated circuits (IC), capacitors,resistors and similar. These can also be arranged on the carrier, inparticular on the functional surface of the floor piece and/or the coverpiece.

The conductor unit can have a board-like design, without having aseparate component. In such a case the conductor unit can be formedentirely of the functional surface. It is conceivable that components ofthe conductor unit are attachable as separate components to thefunctional surface, without the conductor unit as a whole being formedby the separate component.

In a further development, at least one carrier of the at least onecarrier may be formed entirely by the functional surface of the floorpiece and/or cover piece. In such a case, a carrier of the electronicmodule formed as a separate component can be fully dispensed with, ifthe functional surface of the floor piece or the cover piece takes overthe function of the carrier previously formed as a separate component.

The conductor track applied to the carrier, for example, to thefunctional surface, can essentially be realized according to theconductor units formed as separate components. The electronic device,however, can have a compact design when the conductor track is applieddirectly to the carrier by injection molding (Molded InterconnectDevices [MID]), by a conductive foil (Inmold-Labeling [IML]) and/or byLaser Direct Structuring [LDS] directly to the carrier such as to thefunctional surface.

Furthermore, the number of housing devices and electronic modulesarranged therein can be reduced if the electronic module includes aplurality of conductor units and/or if the electronic module forms acommon control unit for a plurality of electrical loads of the rear-viewdevice, wherein each electrical load is or can be functionally assignedwith at least one conductor unit and wherein in particular at least onemain conductor unit includes a driver circuit via which the conductorunits functionally assigned to the electrical loads are individuallyand/or jointly controllable.

This allows combining the electronic modules previously operatedseparately and independently of one another in a common electronicmodule. In this way, the number of housing devices to be allowed for canalso be reduced to a single housing device, in which the commonelectronic module is arranged. This allows the rear-view device to havea compact design with fewer components, since less space is allowed forto accommodate the electronic device.

The at least one retaining unit may include at least one first retainingmeans, which together with the cover piece and/or the floor piece formsa common component, such as an injection molded part.

If the first retaining means of the retaining unit with the cover pieceor the floor piece forms a common component, in particular aninjection-molded part, the electronic device can be designed with lesscomponents and the ease of assembly further increased.

It has further proven advantageous if the housing device can be or isfixed by the retaining unit, in particular by the first retaining means,detachably, in particular by means of a rear grip, in or on therear-view device and/or if the first retaining means includes anexternally threaded section on the cover piece or on the floor piece, alatching element, such as clips or a bayonet fitting, and/or a screw orbolt element.

In a further development of the abovementioned exemplary embodiment ithas proven advantageous if the retaining unit includes a secondretaining means fixed in or on the rear-view device, in particular fixedto a retaining plate of the rear-view device, including an internallythreaded section, which is able to interact with the first retainingmeans designed as externally threaded section, including a rear-grippingreceiving means interacting with the first retaining means designed as alatching element and/or an accommodation for the first retaining meansdesigned as a screw or bolt element.

When manufacturing the electronic device individual components of theelectronic module are arranged mechanically on the functional surface ofthe cover piece and/or of the floor piece. Here the tool used forassembling the components of the electronic module runs parallel to aplane of the functional surface of the cover piece and/or of the floorpiece, said plane being spanned by vectors in x and y direction, whereinwhen joining individual components transversally to this plane, the toolruns along a z direction. In order to keep the movement in z directionlow, it has proven advantageous if the first retaining means is fixedwith a first end to an end of the cover piece or the floor pieceopposite of the functional surface of the cover piece or the floor pieceand is arranged with a second end extending in the direction of thefunctional surface, wherein the first retaining means is designed toextend without overlapping to the plane of the functional surface andthe second end has a distance from the plane of the functional surface.

For example, the first retaining means may be designed as a clip. Insuch a case, the retaining means designed as clips may extend in a zdirection without protruding beyond the functional surface. This meansthat wide assembly paths of the tool used for assembly, which would benecessary for retaining means protruding beyond the functional surface,can be prevented in order not to damage the retaining means.

If the first retaining means, for example, includes an externallythreaded section on the cover piece or on the floor piece of the housingdevice and the second retaining means includes an internally threadedsection, the electronic device can be readily fixedly screwed into therear-view device without tooling.

If the first retaining means includes a latching element and the secondretaining means a receiving means interacting with the latching means,the electronic device can be assembled simply by clipping the electronicdevice in the rear-view device. Furthermore, in such a case themaintenance of the electronic device is also simplified, since theelectronic device can be mounted on the rear-view device without toolingor removed without tooling by releasing the clip connection.

The electronic device may be connected with a power source if the atleast one protruding and externally accessible contact section of the atleast one contact means includes at least one pin, in particular aplurality of pins, via which the electronic module can be or isconnected with at least one power source and/or with at least oneelectrical load.

Furthermore, in one example of the electronic device, the electronicdevice may include at least one energy storage arranged in the cavity ofthe housing device and functional assigned in the electronic module forstoring and releasing electrical energy.

In such a case it is for example possible to hold an energy reserveindependent of the power source in order for example to balance peaks orin order in the event of a power supply failure to keep a reserve ofenergy available in order, for example, to maintain warning lightfunctions for at least a limited time.

In order to simplify joining of the cover piece to the floor piece andto reduce the danger of tilting when joining the cover piece to thefloor piece, the cover piece and the floor piece may include acylindrical section by which, when they are being joined, they can beslid into each other. They may be slid concentrically or telescopically,and the cover piece may include an edge section protruding radially withrespect to the cylindrical section and extend fully around the outersurface of the cover piece, which when the cover piece and the floorpiece are joined forms an end stop.

As a result of the round shape, an even distribution of the clampingforce of the retaining unit may be achieved and through the provision ofa uniform, round, contact area, a good sealing surface may be madeavailable.

In a further development, the cover piece and/or the floor piece mayhave a pot-like design, where at least the cover piece includes anextensive base plate adjacent to the cylindrical section, which runstransversally or inclined to the axis of the cylindrical section, and onits side turned towards the floor piece the functional surface isarranged and on its side turned away from the floor piece and surroundedby the cylindrical section the contact section of the contact means isarranged.

As a result of the floor piece and the cover piece each being designedwith a cylindrical section, which when they are being joined can beconcentrically and telescopically slid into each other, a uniformcontact area is made available. In this way a gap existing between thefloor piece and the cover piece can be kept small. The electronic devicemay include at least one sealant arranged between the cover piece andthe floor piece, in particular between the floor piece and the edgesection of the cover piece, through which the cavity of the housingdevice can be sealed with respect to a gap existing between cover pieceand floor piece.

In this way an ingress of moisture and dirt into the cavity isprevented, through which danger of contamination of or damage to theelectronic module is reduced.

The electronic device can be particularly easily assembled anddisassembled, for maintenance purposes, if the floor piece of thehousing device includes a one-piece element of a component, inparticular a one-piece injection-molded part, such as the retainingplate, of the rear-view device. In such a case the individual componentsof the electronic device can be pre-assembled so that for final assemblyjust the cover piece, to which the electronic module, the firstretaining means of the retaining unit as well as the sealant are fixed,is screwed or glued to the floor piece. In this way the previousplurality of individual electronic modules with the previous pluralityof housing devices, which in each case were formed by a plurality ofseparate components, can be assembled and disassembled in a singlemovement.

The electronic device can furthermore be manufactured with reducedweight and economically, if the floor piece, the cover piece, the firstretaining means, and/or the second retaining means includes a plastic.

The electronic device can be designed as a lighting module, inparticular for a perimeter light of the rear-view device.

A rear-view device may include at least one electronic device asdescribed herein. The rear-view device can contain at least onereflective element and/or at least one camera. The electronic device andthe rear-view device have proven to be advantageous in a number ofrespects:

Because a floor piece and/or the cover piece includes a functionalsurface turned towards the cavity, which at least partly forms thecarrier of the conductor unit, the electronic device can be designedwith a reduced number of components.

Because in the housing device a plurality of conductor units can bearranged, which form a common electronic module, the previous pluralityof electronic devices can be arranged in a common electronic device,such as in a common housing device. In this way, the space that has tobe allowed for in the rear-view device is reduced.

Also described is a head section and a rearview device which can bedesigned in a compact manner device as described in U.S. patentapplication Ser. No. 15/000,754, which is hereby incorporated byreference herein in its entirety for all purposes.

This object is attained by a head section by means of the fact that thehousing section and the lid section tightly seal the hollow area towardsthe outside over at least almost the entire circumference.

Due to the fact that the hollow area is surrounded at least almost overits entire circumference towards the outside, the hollow area isprotected against penetration by dirt and humidity. This makes itpossible to arrange the at least one electronic unit in the hollow areawithout its own seal. This makes it possible to create a compact designfor the head section.

In general, it is feasible to provide the electronic unit with its ownhousing, with which it can be arranged in the hollow area between thehousing section and the lid section. However, it has been shown to beadvantageous when the at least one electronic unit can be arranged or isarranged without housing in the hollow area.

The housing section and the lid section can in general be connected toeach other in any manner required. With one embodiment of the headsection according to the invention, it is provided that the housingsection and the lid section can be locked or are locked relative to eachother at a coupling portion in such a manner that they overlap eachother, and in particular form an undercut. When the lid section and thehousing section form an undercut, it is easily possible to achieve afixed connection of the two components. In particular, in such cases,the housing section and the lid section can be locked to each otherwithout using tools, e.g. by means of clips.

In general, it is feasible to create the coupling portion only insections. Preferably, the coupling portion is designed to surround thecircumference.

It is feasible to make the rear view means relatively mobile in relationto the housing section. This can be the case, for example, when the lidsection and/or the housing section is created at least in sections froma flexible, pliable material, such as a plastic membrane. However, therearview means may be locked relative to the housing section. In suchcases, the rearview means can be set by adjusting the head section.

The rearview means can include a component which can be separated or isseparated from the lid section. In such cases, the lid section can forexample be adhered, or locked for example by spraying a reflectivecoating on the lid section. In one embodiment of the head sectionaccording to the invention, it is provided, however, that the lidsection and the rearview means includes a single-piece component.

This makes it possible to reduce the number of components of the headsection.

In general, it is feasible to create the lid section in a disc form.However, the lid section may be designed as a type of clamp, andincludes a flat portion, which in particular includes the rearviewmeans, and at least one edge portion which extends transverse ordiagonally to the flat portion. In such cases, the lid section can belocked to the housing section like a clamp with the at least one edgesection. The edge section can here be adjacent to the housing sectionfrom the inside, or grips the housing section from the outside.

The housing section and the lid section can be created from any materialrequired. When the lid section and the rearview means include a combinedsingle-piece component, i.e. when the rearview means is part of the lidsection, it has been shown to be advantageous when the lid sectionincludes a multiple-part component, wherein the flat portion includes afirst lid part, in particular a plastic part, and the edge portionincludes a second lid part, in particular a plastic part.

In general, it is feasible that the multiple-part component includes adual-part plastic section. When the lid section has several functions,however, further plastic parts can be provided.

Due to the fact that the edge section can include another plastic part,such as the flat portion, the edge section can be designed to form atight seal. The electronic unit can include a lighting unit for example.The light from the head section generated by the lamp can penetrateoutwards through the light window. In such cases, the electronic unitcan include a repeatedly flashing light or lighting for the areaimmediately surrounding a motor vehicle.

In an aspect, it is provided that the housing section includes a firsthousing part, in particular a plastic part, which lies directly on thehollow area and which has a coloring which is in particular essentiallyopaque and/or non-translucent, where the first housing part includes anopening in the area of the light window. Because the first housingcomponent is opaque and non-translucent, an attractive appearance can beachieved. Because an opening is provided in the first housing part, thelight from the electronic unit can penetrate outwards.

In order to prevent penetration by dirt or humidity, with a furtherdevelopment of the latter inventive embodiment, it is provided that anoptical element, such as an optical fiber and/or light disc, can bearranged in and/or on the opening of the first housing part of thehousing section and that a housing seal can be arranged or is arrangedbetween the first housing part of the housing section and the opticalelement. Due to the provision of the housing seal between the opticalelement and the opening of the housing section, the hollow area istightly sealed towards the outside. As a result, again, no separatehousing is required for the electronic unit.

As a supplement or an alternative to the provision of a housing seal, ithas been shown to be advantageous when a second housing part, inparticular a plastic part, is arranged in such a manner that it lies ona surface of the first housing part which faces away from the hollowarea, and is essentially translucent and/or transparent at least in thearea of the light window, and in particular in the area of the lightwindow is designed as an optical element such as an optical fiber and/orlight disc.

Because a second housing part is adjacent to the first housing part,which in particular covers the opening provided in the first housingpart towards the outside, no housing seal is required. Because thesecond housing part is translucent and/or transparent, light from theelectronic unit which is designed as a lighting unit can penetrateoutwards from the hollow area of the head section.

The rearview means can include a reflective means and/or a display meanssuch as a screen, in particular an LED or LCD screen. When the displaymeans includes a screen, the screen can be arranged on the flat portionof the lid section. It is furthermore feasible that the lid section, atleast in the portion on which the LED or LCD screen is arranged, isarranged in a transparent and/or translucent manner, and the screen isarranged on the side of the flat portion of the lid section which facestowards the hollow area.

The electronic unit can include a setting facility for the rear viewdevice. This makes it possible to set the rearview device in a simplemanner. The setting facility can be arranged on the upper surface of theflat portion of the lid section which faces towards the hollow area.

The setting facility may include a setting unit with at least onelighting means which can be locked or is locked relative to a rear viewmeans, and by means of which a directable or directed light beam can beemitted, which is at least almost solely perceivable in a specifiedoperating position by a driver of a motor vehicle and/or a control unit.The lighting means can include a coiled wire bulb, an LED or a laser.

Due to the fact that the light beam can be detected at least almostsolely in the specified operating position by a driver of a motorvehicle and/or by a control unit, the rearview means may be easy toadjust in a position which conforms to the regulations.

In order to enable light to exit, the housing section and/or the lidsection, in particular the edge portion, may include a transparentand/or translucent area through which the light beam emitted by thelighting means can penetrate outwards at least almost unimpeded.

This makes it possible for light which is emitted by the lighting meansto penetrate outwards from inside the rear view device and to beperceivable from the outside, where in the hollow area of the housing,it is at the same time protected against environmental influences.

The transparent and/or translucent area can in general be designed inany manner required. The transparent and/or translucent area may includea recess, in particular throughout, and/or a translucent and/ortransparent material such as glass, in particular smoked glass, orplastic.

In general, it is feasible that the light beam emitted from the lightingmeans is sufficiently bundled in order to be perceivable almost solelyin the specified operating position by the driver of a motor vehicleand/or the control unit. Furthermore, the setting unit may include atleast one optical element which can be functionally assigned or isassigned to the lighting means, with which the light beam emitted by thelighting means can at least be bundled.

Furthermore, the object is attained by means of a rearview device, suchas an internal or external mirror, for a motor vehicle with at least onehead section, in particular with at least one of the features describedabove.

Finally, the object is attained by means of a motor vehicle with atleast one rear view device with at least one of the features describedabove and/or with at least one head section, in particular with at leastone of the features described above.

Because the lid section and the housing section surround a hollow areain an almost entirely sealing manner, electronic devices can be providedin the hollow area which require no housing. As a result, the headsection and the rearview device can be compact in design.

The present invention also provides a plastic substrate coated with adecorative coating as described in U.S. patent application Ser. No.15/124,310 and incorporated herein by reference in its entirety for allpurposes, the decorative coating including a spectrally controllingsystem and a stress controlling system, the spectrally controllingsystem being multiple layers and optionally including a protectivelayer, and the stress controlling system being at least a single layerbetween the spectrally controlling system and the substrate,

The multiple layers of the spectrally controlling system may beabsorbing layers alternating with transparent layers, the opticalthickness of the spectrally controlling system being selected such thatthe decorative coating achieves a desired optical effect, and at leastone layer of the stress controlling system has a compressive stress ofan amount such that the overall residual stress of the decorativecoating is compressive when measured in the absence of the optionalprotective layer.

To understand the following description, it is important to understandwhat is herein meant by the phrase “desired optical effect” and theimpact that the determination of the desired optical effect subsequentlyhas upon how the decorative coating is spectrally tuned to provide thecoated substrate with that desired optical effect.

The desired optical effect will be a desired appearance for a surface,or a part of a surface, of a product (when viewed from the front) thatincludes a coated substrate in accordance with the present invention.The desired optical effect will be made up of a combination of a desiredtransmitted color, a desired specular reflected color, and a desireddiffuse reflected color, taking account of the combined influence of thedecorative coating, the plastic substrate and the presence or not ofbacklighting. In this respect, the plastic substrate needs to be takeninto account as the substrate may itself be tinted or clear, or mayinclude embedded particles to provide the uncoated substrate with a hazyappearance, or may have one or both of its (uncoated) surfaces bearing atexture such as might be adopted to provide a “brushed-metal”appearance. While all of these attributes will contribute to the overallappearance of the final product, it should be appreciated that it is thedecorative coating, and specifically the spectrally controlling system,that is tunable in the present invention to permit the achievement ofthe desired optical effect.

In relation to a determination of a desired transmitted color, a desiredspecular reflected color, and a desired diffuse reflected cp;pr,reference throughout this specification to a “color” is reference to acolor that is defined by measured L*, a* and b* values in accordancewith the 1976 CIE L*a*b* Space (or CIELAB) color model, which is anapproximately uniform color scale organized in cube form. In theorthogonal a* and b* color axes, positive a* values are red, negative a*values are green, positive b* values are yellow and negative b* valuesare blue, while the vertical scale for lightness (or greyscale) L* runsfrom 0 (black) to 100 (white), allowing the positioning of a total colorE in three points. The Chroma (C*) of the color is defined as(a*.sup.2+b*.sup.2), and is used to quantify the magnitude of the colorindependent of its lightness.

It will also be appreciated that reference to “transmitted” color and“reflected” color are references to the color of light after having beentransmitted through an object (“transmitted color”) or after having beenreflected by the surface of an object (“reflected color”). Furthermore,with respect to reflected color, “specular reflection” is a reference tothe mirror-like reflection of light from the surface of an object, inwhich light from a single incoming direction is reflected into a singleoutgoing direction, whereas “diffuse reflection” is of course areference to incoming light being reflected in a broad range ofdirections.

The spectrally controlling system is thus ideally used to modifyspectral reflection and transmission, so that the desired optical effectis achieved for the coated substrate. In particular, the opticalthickness of the spectrally controlling system is selected such that thedecorative coating achieves the desired optical effect. In one form, themagnitude of the spectral transmission is primarily controlled by thetotal optical thickness of the absorbing layers within the spectrallycontrolling system. However, both reflected and transmitted color iscontrolled by an interference effect between the absorbing andtransparent layers within the spectrally controlling system. Bycontrolling the optical thickness of all layers of the spectrallycontrolling system, including both the absorbing and transparent layersas necessary, this interference effect can be “tuned” so that thedesired reflected and transmitted color can be achieved.

In a preferred form, the optical thicknesses are selected firstly toachieve the desired transmission, which is controlled by the combinedoptical thicknesses of the absorbing layers. Having established thistarget, the optical thickness of the transparent layers, and the ratioof the thickness of the individual absorbing layers, are further refinedthrough the use of thin film modelling software (such as Tfcalc™) toachieve a desired reflective color through an interference effect.

For example, a required product may need a gloss black appearancepositioned in front of an illuminated display. This could be achievedvia a decorative coating with low, neutral reflective color withnegligible diffuse reflected color. This would present as a desiredtransmitted color of L*=44, a*=0, b*=0 and a desired specular reflectedcolor of L*=25, a*=0, b*=0.

Taking this example further, using a CrZr alloy as an absorbing layer, acombined thickness of absorbing layers to achieve a % T of .about.14%might be .about.16.4 nm. To achieve the desired interference, a fourlayer stack could be used such that the combined thickness of theabsorbing layers was split into two layers, 9.7 nm and 6.7 nm, thethicker layer deposited first. An SiO.sub.2 transparent layer can thenbe used to split the two absorbing layers, and a final SiO.sub.2 layerdeposited on top of that. In this example, a spectrally controllingsystem including of CrZr/SiO.sub.2/CrZr/SiO.sub.2 is utilized, where thethickness of the SiO.sub.2 layers in combination with the CrZr layers isthen optimized through a thin film modelling program to achieve thedesired reflected color.

In this respect, it will be appreciated that “optical thickness” is adimensionless measure of how much a given material retards the passageof light therethrough, derived from the multiplication of the complexrefractive index and the distance travelled through the material by alight beam. It is also known as the optical path length. The complexrefractive index is a number made up of a real part (defined asrefractive index) and an imaginary part (defined as the extinctioncoefficient). It then will be appreciated that for any given layer of amaterial, the optical thickness (t) is defined as the material'srefractive index (n) multiplied by the layer's physical thickness (d),normalized at the handled wavelength, for a refractive index at thiswavelength. By way of example, optical thickness can thus be calculatedusing a refractive index at a wavelength of 550 nm. For example,chrome:n.sub.550=3.17, having a physical thickness of 50 nm correspondsto an optical thickness of 0.288, while SiO.sub.2:n.sub.550=1.455,having a physical thickness of 100 nm corresponds to an opticalthickness of 0.265.

It should also be appreciated that reference throughout thisspecification to an “absorbing layer” is a reference to a layerincluding a material, or a blend of materials, having a measured opticalextinction coefficient greater than 1 in the spectral range of 400 to1000 nm. Furthermore, it will be understood that reference to a“transparent layer” throughout this specification is a reference to alayer including a material, or a blend of materials, having a measuredoptical extinction coefficient of less than 1 in the spectral range of400 to 1000 nm.

If utilized in the decorative coating of the present invention, aprotective layer would be applied on top of the spectrally controllingsystem (and thus be an outermost layer) to provide enhanced abrasionresistance, fingerprint resistance and ‘ easy clean’ functionality.Suitable materials for such a protective layer could be plasmapolymerized hexamethyldisiloxane (HMDSO), fluoro polymer based coatingsdeposited via evaporation or liquid transfer techniques, or a liquidhardcoat applied via spin, dip, spray or flow coating techniques, withor without particulate additives for haze control (matt additive).

If a protective layer is used, it forms part of the spectrallycontrolling system (and thus part of the decorative coating) and as suchits influence on the desired optical effect also needs to beaccommodated, in the same manner as outlined above. Indeed, in the formof the invention where a protective layer is adopted, it would thus bethe combined optical thickness of the protective layer plus theabsorbing and transparent layers that would be selected such that thedecorative coating achieved the desired optical effect.

For the absorbing layers of the spectrally controlling system, and asmentioned above, these are layers including a material, or a blend ofmaterials, having a measured optical extinction coefficient greater than1 in the spectral range of 400 to 1000 nm metals. Preferably, thesematerials are metals, metalloids, metal alloys or a mixture thereof thathave a refractive index such that the sum of the refractive index andthe extinction coefficient is greater than 2, while maintaining theextinction coefficient greater than 1. For the transparent layers of thespectrally controlling system, and again as mentioned above, these arelayers including a material, or a blend of materials, having a measuredoptical extinction coefficient less than 1 in the spectral range of 400to 1000 nm metals. Preferably, these materials are metals, metalloids,metal alloys (or a mixture thereof) that have a refractive index suchthat the sum of the refractive index and the extinction coefficient isless than 3, while maintaining the extinction coefficient less than 1.

In this form, the spectrally controlling system is an interferencesystem made up of alternating layers of materials of differentrefractive indices, ideally with a relatively high refractive indexcontrast between adjacent layers. In this respect, such a refractiveindex contrast can be achieved by the selection of transparent layers ofa material with a suitably low refractive index and absorbing layers ofa material with a suitably high refractive index. In this respect, thedifference in refractive index should be as high as possible to reduceoverall film thicknesses required to produce the desired reflectedcolor. It is desirable to have the low refractive index material of thelowest possible of practical materials.

With this in mind, suitable materials for the absorbing layers may beselected from the group of metals, metalloids and metal alloysincluding: chromium, aluminum, titanium, nickel, molybdenum, zirconium,tungsten, silicon, niobium, tantalum, vanadium, cobalt, manganese,silver, zinc, indium, germanium, tin and mixtures thereof and an oxide,nitride, boride, fluoride or carbide thereof, and mixtures thereof. Mostpreferably, at least one layer is chromium, or a chromium mixture, suchas Cr—Zr, Cr—Ni or Cr—Mo, or carbides or nitrides thereof, such as Cr—N.

Suitable materials for the transparent layers may be selected from thegroup of metals, metalloids and metal alloys including: boron, silicon,germanium, antimony, tellurium, polonium, niobium, zirconium, magnesium,tin, tantalum, aluminum, chromium, titanium and mixtures thereof; and anoxide, nitride, boride, fluoride or carbide thereof, and mixturesthereof. Most preferably, at least one layer is formed from an oxidesuch as SiO.sub.2.

Preferred deposition methods that may be adopted for applying themultiple layers of the spectrally controlling system to the stresscontrolling system can also be chosen from any suitable vacuum vapordeposition systems, such as thermal evaporation, electron beamevaporation (with or without ion beam assistance) or sputter deposition.Sputter deposition is the preferred method. Additionally, the surface ofthe plastic substrate may first be subjected to a surface treatment toimprove adhesion between the stress controlling system and thespectrally controlling system. The surface treatment may be selectedfrom any of plasma discharge, corona discharge, glow discharge and UVradiation.

The preferred optical thickness of each individual layer of thespectrally controlling system will of course depend on the desiredoptical effect. Therefore, for each different product, the expectationis that there will be a different set of “preferred opticalthicknesses”. Noting this, in a spectrally controlling system that is afour layer stack, such as in the example provided above, it is envisagedthat the first CrZr layer might have a preferred physical thickness in arange between 2 and 40 nm. The second layer might have a physicalpreferred thickness in a range between 20 and 200 nm. The second layermight have a more preferred physical thickness in the range between 48and 101 nm. The third layer might have a preferred physical thickness ina range between 2 and 40 nm. The third layer might have a more preferredphysical thickness in a range between 6.7 and 25 nm. The fourth layermight have a preferred physical thickness in a range between 15 and 200nm. The forth layer might have a more preferred physical thickness in arange between 15 and 40 nm.

Turning now to a description of the stress controlling system, asmentioned above the stress controlling system ideally consists of one ormore layers of a material that can ensure that the overall residualstress of the decorative coating will be compressive (when measured inthe absence of an optional protective layer) but also that will becompatible with the plastic substrate. In this respect, a “compatible”layer will be one that displays good adhesion to the plastic substrate.

In this respect, in this stress range it has been found that a coatedsubstrate will exhibit good performance throughout durability tests,such as salt spray, thermal shock, dry heat, immersion and humiditytests. Throughout this specification, this range will be referred to as“the desired stress window”. Having said that, an alternative range forthe desired stress window is less than −6 MPa, or less than −63 MPa, orless than −76 MPa, or less than −100 MPa, or less than −110 MPa, or lessthan −112, or less than 160 MPa. Furthermore, the lower bounds of thestress window may be −360 MPa or greater, −359 MPa or greater, −300 MPaor greater, −250 MPa or greater, or −200 MPa or greater. Furthercombinations of these ranges are also contemplated by the presentinvention. For example the stress window may be between 0 MPa to −300MPa; −63 MPa to −300 MPa, −75 MPa to −300 MPa, −110 MPa to −300 MPa or 0MPa to −250 MPa etc.

As mentioned above, the stress controlling system is ideally used tobalance the overall residual stress of the decorative coating, such thatthe overall residual stress is maintained in the desired stress window.In this respect, when the combined optical thickness of the absorbinglayers and the transparent layers (and of the protective layer, ifpresent) are selected such that the spectrally controlling systemprovides the desired optical effect, the stress controlling system needsto include a layer of a compressive stress of a suitable amount so as tomaintain the overall residual stress of the decorative coating in thedesired stress window.

Preferred deposition methods that may be adopted for applying the one ormore layers of the stress controlling system to the plastic substratecan be chosen from any vacuum vapour deposition system, such as thermalevaporation, electron beam evaporation (with or without ion beamassistance) or sputter deposition. Sputter deposition is the preferredmethod. Additionally, the surface of the substrate may first besubjected to a surface treatment to improve adhesion between the stresscontrolling system and the substrate. The surface treatment may beselected from any of plasma discharge, corona discharge, glow dischargeand UV radiation.

In one form, the stress controlling system can be tuned to achieve thedesired stress window by optimizing the deposition parameters of one ormore of its layers. These parameters include sputter power, gaspressure, nitrogen gas doping and coating thickness. Stress can also betuned to be more compressive (or less tensile) by introducing a thermalstress component by way of substrate heating, or by conducting apretreatment process directly before the deposition of the stresscontrolling system. The interaction of the stress controlling systemwith the spectrally controlling system is complex and the tuning of theoverall residual stress is ideally conducted with reference to theentire decorative coating being a complete coating ‘stack’.

In this respect, the overall residual stress is the measured stressprofile of the stress controlling system and spectrally controllingsystem (without the protective layer, even when such a protective layerwill be utilized) as a complete stack deposited on a glass microscopecover slide. The stress measurement is obtained by placing the glassslide into a stress measurement device (such as a Sigma PhysikSIG-500SP) before and after coating deposition.

Typically, there is little scope to tune the stress in the spectrallycontrolling system as the layers need to maintain near perfect (andconsistent) composition to achieve the desired optical effect, meaningthe resultant stresses in the spectrally controlling system tend not tobe controllable and will be tensile or sometimes only slightlycompressive. It is thus the stress controlling system that is tuned tobring the overall residual stress of the decorative coating into thedesired stress window. If, for example, the spectrally controllingsystem is highly tensile, the stress controlling system will need to becompressive in stress and of a higher magnitude to achieve the desiredstress window.

The stress controlling system will preferably be a single layer of amaterial which, when deposited, produces a high level of compressivestress. Materials known for their compressive stress are SiO.sub.x,SiO.sub.xN.sub.y, CrN.sub.x, NbO.sub.x, TaO.sub.x, and ZrO.sub.x, wherex and y are both preferably between 0.1 and 2.0.

The stress controlling system may be a multilayer system, which may berequired when the preferred stress controlling layer is not compatible(displays poor adhesion) with the substrate. In this case, a compressiveor slightly tensile compatible layer would be deposited on the substrateand then a highly compressive layer would be deposited on top. Examplesof a multilayer system could be CrNNb.sub.2O.sub.5. It is envisaged thatsuch a multilayer stress controlling system would obtain a highlycompressive stress which is compatible with the substrate.

It will thus be apparent that when the desired optical effect isrequired to be altered to be another desired optical effect, such as bymaking different optical thickness selections for either or both of theabsorbing layers and the transparent layers of the spectrallycontrolling system to give rise to a different color, concomitantchanges will likely also be required for the stress controlling systemto ensure that the overall residual stress of the decorative coating ismaintained in the desired residual stress window.

The present application thus also provides a method for applying adecorative coating to a plastic substrate, the decorative coatingproviding the coated substrate with a desired optical effect, thedecorative coating including a spectrally controlling system and astress controlling system, the spectrally controlling system beingmultiple layers and optionally including a protective layer, and thestress controlling system being at least a single layer, wherein themultiple layers of the spectrally controlling system are absorbinglayers alternating with transparent layers, the method including:

a) determining the desired optical effect;

b) determining a suitable spectrally controlling system that willprovide the desired optical effect, with reference to a required opticalthickness for the spectrally controlling system;

c) determining a suitable stress controlling system that has acompressive stress of an amount such that the overall residual stress ofthe decorative coating compressive when measured in the absence of theoptional protective layer;

d) coating the suitable stress controlling system upon the plasticsubstrate;

e) coating the suitable spectrally controlling system upon the stresscontrolling system; and

f) thereby forming a coated plastic substrate with the desired opticaleffect.

The plastic substrate of the present invention may be formed from anysuitable plastic material. For example, a plastic substrate may beformed from a material selected from the group including polyacrylate,polyester, polystyrene, polyethylene, polypropylene, polyamides,polyamides, polycarbonate, epoxy, phenolic,acrylonitrile-butadiene-styrene, acrylonitrile-styrene-acrylates, acetaland blends of these. Preferred plastic substrate materials includepolycarbonate, poly (2,2′-dihydroxyphenylpropane) carbonate,polydiethyleneglycol bis(allyl carbonate), polymethylmethacrylate andpolystyrene, or blends thereof. In preferred forms, the substrate willtypically have a physical thickness in the range of 0.1 mm to 20 mm,more preferably in the range of 1 mm to 5 mm, and most preferably in therange of 2 mm to 3 mm.

A product bearing the decorative coating as described herein may alsoinclude other coatings either between the decorative coating and thesubstrate, within the decorative coating, such as the protective layermentioned above that can optionally be a part of the spectrallycontrolling system of the decorative coating, or be upon the decorativecoating. In particular, it is envisaged that in some embodiments it willbe advantageous to include a hard coating between the decorative coatingand the substrate. In this form, the hard coating is a protective layerwhich does not contribute to the overall desired optical effect, whilein other embodiments an external protective layer upon the decorativecoating will itself be a hard coating.

In this respect, a coating that is said to be a “hard coating” is acoating that is harder and stiffer than the substrate, whereby itincreases the abrasion resistance of that substrate. Such an abrasionresistant hard coating is one that reduces damage due to impacts andscratching. Abrasion resistance can be measured through tests such asASTM F735 “Standard Test Method for Abrasion Resistance of TransparentPlastics and Coatings Using the Oscillating Sand Method”, ASTM D4060“Standard Test Method for Abrasion Resistance of Organic Coatings”, bythe Taber Abrader, or by using the well-known Steelwool Test.

Furthermore, some plastic substrates can be damaged by certain solvents;for example, polycarbonate is damaged by acetone. It is a requirementfor many products that might be suited to the decorative coating of thepresent invention that they be “chemically resistant”, which is areference to an ability to withstand exposure to normal solvents such asdiesel fuel, petroleum, battery acid, brake fluid, antifreeze, acetone,alcohol, automatic transmission fluid, hydraulic oil and ammonia basedwindow cleaners. In this respect, it will be appreciated that ahardcoating ideally provides a product bearing the decorative coating ofthe present invention with such chemical resistance.

A hard coating is preferably formed from one or more abrasion resistantlayers, and may include a primer layer that bonds well to a plasticsubstrate and forms a preferable material for subsequent abrasionresistant layers. The primer layer may be provided by any suitablematerial and may for example be an organic resin such as an acrylicpolymer, a copolymer of acrylic monomer and methacryloxysilane, or acopolymer of a methacrylic monomer and an acrylic monomer having abenzotriazole group or benzophenone group. These organic resins may beused alone or in combinations of two or more.

[1] The abrasion resistant layers are preferably formed from one or morematerials selected from the group consisting of an organo-silicon, anacrylic, a urethane, a melamine or an amorphous SiO.sub.xC.sub.yH.sub.2.Most preferably, the abrasion resistant layer is an organo-siliconlayer, due to its superior abrasion resistance and compatibility withphysical vapour deposited films. For example, an abrasion resistantlayer including an organo-silicon polymer can be formed by forming alayer of a compound selected from the following compounds by a methodsuch as dip coating or the like and then curing the layer:trialkoxysilanes or triacyloxysilanes such as methyltrimethoxysilane,methyltriethoxysilane, methyltrimethoxyethoxysilane,methyltriacetoxysilane, methyltripropoxysilane, methyltributoxysilane,ethyltrimethoxysilane, ethyltriethoxysilane, vinyltrimethoxysilane,vinyltriethoxysilane, vinyltracetoxysilane, vinyltrimethoxyethoxysilane,phenyltrimethoxysilane, phenyltriethoxysilane, phenyltriacetoxysilane,gamma-chloropropyltrimethoxysilane, gamma-chloropropyltriethoxysilane,gamma-chloropropyltripropoxysilane,3,3,3-trifluoropropyltrimethoxysilanegamma-glycidoxypropyltrimethoxysilane,gamma-glycidoxypropyltriethoxysilane,gamma-(beta-glycidoxyethoxy)propyltrimethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltriethoxysilane,gamma-methacryloxypropyltrimethyoxysilane,gamma-aminopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane,gamma-meraptopropyltrimethoxysilane,gamma-mercaptopropyltriethoxysilane,N-beta(aminoethyl)-gamma-aminopropyltrimethoxysilane,beta-cyanoethyltriethoxysilane and the like; as well as dialkoxysilanesor diacyloxysilanes such as dimethyldimethoxysilane,phenylmethyldimethoxysilane, dimethyldiethoxysilane,phenylmethyldiethoxysilane, gamma-glycidoxypropylmethyldimethoxysilane,gamma-glycidoxypropylmethyldiethoxysilane,gamma-glycidoxypropylphenyldimethoxysilane,gamma-glycidoxypropylphenyldiethoxysilane,gamma-chloropropylmethyldimethoxysilane,gamma-chloropropylmethyldiethoxysilane, dimethyldiacetoxysilane,gamma-methacryloxypropylmethyldimethoxysilane,gamma-metacryloxypropylmethyldiethoxysilane,gamma-mercaptopropylmethyldimethoxysilane,gamma-mercaptopropylmethyldiethoxysilane,gamma-aminopropylmethyldimethoxysilane,gamma-aminopropylmethyldiethoxysilane, methylvinyldimethoxysilane,methylvinyldiethoxysilane and the like.

The abrasion resistant layers may be coated onto a plastic substrate bydip coating in liquid followed by solvent evaporation, or by plasmaenhanced chemical vapour deposition (PECVD) via a suitable monomer.Alternative deposition techniques such as flow coating and spray coatingare also suitable. To improve the abrasion resistance of the hardcoating, subsequent coatings of the abrasion resistant layer may beadded, preferably within a 48 hour period to as to avoid aging andcontamination of the earlier coatings.

The thickness of an abrasion resistant layer is preferably selected toassist in providing adequate abrasion resistance. In this respect,adequate abrasion resistance is regarded herein as being a Bayerabrasion ratio of 5 with respect to an uncoated plastic substrate (suchas a polycarbonate), or alternatively by a Taber abrasion test withdelta haze less than 15% after testing with a 500 g load and CS10F wheelat 500 cycles, (% haze being measured as per ASTM D1003). With theserequirements met, when an organo-silicon is used as an abrasionresistant layer, the thickness of the hard coating is preferably in therange of from about 1 to about 15 microns, and is most preferablybetween 3 and 7 microns.

A refinement to the visual appearance can be achieved by patterning thesubstrate. For example, through the use of a patterned injection mold, apattern can be formed on the front surface of a substrate. An example ofa desirable optical effect is to replicate brushed stainless steel, andit has been found that parallel lines of random length (between 1 and 5cm) positioned closely adjacent each other can achieve this appearancewhen subsequently coated with the present invention.

A further refinement to improve the visual comparison to brushedstainless steel is the incorporation of a matting additive to a hardcoating protective layer which is applied to a patterned substrate. Inthis respect, it is known that a matt effect is achieved due to theuneven surface produced by the small (usually about.5 .mu·m) particlesof a matt additive. By alteration of the protective layer through theaddition of matting additives to the hard coat, a “satin” appearance canalso be achieved. This is characterized by a significant diffusereflected component (Diffuse Reflection about between 10% and 30%,preferably 16% and a Specular Reflection of .about.8%).

In a further form of the present invention, the decorative coating maybe overcoated with a protective layer to further enhance the abrasionresistance or to assist with the cleanability of the coated product. Forexample, a protective layer may be formed from a material exhibiting thefollowing characteristics, including hydrophobic, hydrophilic,lipophobic, lipophilic and oleophobic characteristics or combinationsthereof, and may include a hard coating (with or without a mattingadditive (particles)) such as that mentioned above.

In terms of possible uses for a decoratively coated plastic substrate inaccordance with the present invention, as foreshadowed above the coatedplastic substrates can be used as designer surfaces on a variety ofconsumer goods including premium automotive interior and exterior trimcomponents, consumer and household goods, as well as fashionablehousehold electronic products, and either as partial or full surfacesfor those goods.

Also, the coated plastic substrates are able to provide illuminatedpatterns for products, sometimes referred to as “hidden ‘til lit”, andback lighting in general, in suitable situations. In this respect, adesired optical effect can be achieved by selecting the correct % R and% T such that a light can be shone through a coating to produce anilluminated pattern. However, when the rear illumination is not present,the visual appearance of the product is such that it appears uniform,such that there is no visible pattern present.

It is the also an object of the present invention to further develop theknown external rear vision device to enhance functionality andefficiency while at the same time reducing size and costs as describedin EP application number 16198759.9, which is incorporated herein byreference for all purposes.

This object is solved by a foot of the base assembly providing aspherical seat for a casing, in particular a lower casing element, ofthe head assembly, and frame means providing at least one spherical seatfor the casing, with the frame means being rigidly attached to the fixedpart or included by the fixed part.

According to the application, the base assembly can include anattachment part for the attachment to the motor vehicle, with theattachment part carrying a control system for or of the articulationassembly, and/or the attachment part guiding cables from the interior ofthe motor vehicles to the interior of the foot, and/or the attachmentpart closing the foot at its end opposite its spherical seat.

It is also proposed that the base assembly includes a carrier part forthe attachment of the fixed part of the articulation assembly and/or ofa fixation part of the frame means, with the carrier part extending fromthe spherical seat of the base assembly, and/or the carrier part guidingthe cables from inside the foot through a cable exit into the headassembly.

Further, it is proposed with the invention that the carrier part is atleast partly arranged within the fixation part, and/or the carrier partis attached to the fixation part by a screw or clip connection and/or bya bayonet attachment.

The frame means can includes a support part supporting the fixed part ofthe articulation assembly, preferably by at least partly encompassingthe fixed part, with the support part in particular having a ring shape,and/or by a clips or snap connection.

Preferred embodiments are characterized in that the frame means includesa first spherical seat for the lower casing element and a secondspherical seat for an upper casing element of the casing, withpreferably the first and second spherical seats of the frame means beingprovided by extensions arranged at opposite ends of the fixation partand/or on the side of support part facing away from the fixed part ofthe articulation means.

With the invention it is proposed that the first spherical seat isprovided by a first extension facing away from the fixed part of thearticulation means and a second extension facing towards the moveablepart of the articulation means, with preferably the support part and thefirst and second extensions form a part of a ring with a cut-outproviding a rim facing towards the moveable part of the articulationmeans.

It is preferred that the fixation means is provided with a cable exit,with the cable exit of the fixation means being aligned with the cableexit of the carrier part, and/or the cable exit of the fixation meansbeing arranged on the side of the fixation means facing away from thefixed part of the articulation means, and/or cables exiting the cableexit of the fixation means being connected to at least one camera and/orat least one light unit at least partly arranged within the headassembly.

Still further it is proposed with the invention that the lower casingelement has a first spherical seat cooperating with the spherical seatof the foot and/or a second spherical seat cooperating with the firstspherical seat of the frame means, with preferably the first and secondspherical seats of the lower casing element being provided by a basepart of the lower casing element.

The lower casing element preferably has an attachment part fixed to themoveable part of the articulation assembly, with preferably theattachment part extending substantially perpendicularly to the base partof the lower casing element, and/or preferably the attachment part andthe frame means being arranged on opposite sides of the unit provided bythe fixed and the moveable parts of the articulation means, and/orpreferably the attachment part encompassing the moveable part at leastpartly, and/or preferably the attachment part and the moveable partbeing connected via a clips, plug and/or snap connection.

In addition, it is proposed that the attachment part is provided with apart ring for partly encompassing the moveable part of the articulationassembly, with preferably the part ring is provided by a cut-outdetermined by the part ring provided by the support part and the firstand second extensions.

The unit can be an actuator for a reflective element, in particular inform of mirror element, being attached to the attachment part.

In addition, it is proposed that the lower casing element carries theupper casing element and/or the camera, and/or a bezel is attached tothe lower and upper casing elements, with the bezel preferablysurrounding the reflective element.

A head assembly of an external rear vision device, in particular in theform of a mirror head of an external rear view mirror, can bearticulated inboard/outboard and up/down using an articulation means, inparticular glass actuator, around a spherical joint, with sphericalseats being provided between parts moving relative to each other suchthat they can rotate around two articulation axes perpendicular to eachother having a common joint point. This ensures the maintenance ofcurrent end user functionality while offering significant smaller mirrorsize, with a reduction of size up to 30%. In addition, the unique layoutof the internal mechanism with its spherical seats enhances packagingand performances.

The articulation assembly is also supported and protected for impactusing the spherical seats, in particular due to the arrangement of framemeans between the articulation assembly and a casing of the headassembly. The casing being assembled from several casing elements, oneof which is secured to the moveable part of the articulation assembly,improves the weight distribution and reduces total housing frontal areaon the vehicle which in turn improves aero performance and, thus,provides a higher fuel efficiency.

The pivot system used for the rear vision device of the invention withthe single pivot point for two articulation axes permits a mirroradjustment movement while providing dynamic mirror performance andmirror impact support.

Further, as discussed in U.S. patent application Ser. No. 15/439,188,which is hereby incorporated by reference herein in its entirety for allpurposes, in another aspect, a mirror assembly includes a mirrorhousing, a reflective element having a first field of view, a reflectivecoating having a second field of view, the second field of view beingwider than the first field of view, and a multi-function backing platesupported by the mirror housing and including a reflective elementsupporting region where the reflective element is supported by themulti-function backing plate and a reflective coating supporting regionwhere the reflective coating is applied to the backing plate.

The reflective coating supporting region may be convex so that thereflective coating is convex and provide a wider field of view.

The reflective element supporting region may include an aperture forreceiving the reflective element, and the reflective coating supportingregion may be thicker than the reflective element supporting region.

The reflective coating may be a chromium-based reflective coating.

In another aspect, the present description relates to a backing plate ora polymeric substrate, wherein the backing plate or polymeric substrateis coated with a reflective coating such as a chromium-based reflectivecoating.

The present description also provides the chromium-based reflectivecoating for a backing plate or a polymeric substrate, wherein thecoating is an alloy of chromium and a dopant material, the dopantmaterial being selected from the hexagonally close-packed transitionmetals, the alloy having a crystal structure of a primary body-centeredcubic phase in coexistence with a secondary omega hexagonallyclose-packed phase. In a preferred form of the present invention, thealloy is a binary alloy of chromium and the dopant material.

The present description also provides a method of forming achromium-based reflective coating on a backing plate or a polymericsubstrate, the method including applying chromium and a dopant materialto the polymeric substrate by physical vapour deposition, the dopantmaterial being selected from the hexagonally close-packed transitionmetals, to form an alloy coating, the alloy coating being applied so asto have a crystal structure of a primary body-centered cubic phase incoexistence with a secondary omega hexagonally close-packed phase. In apreferred form of the present invention, the alloy is applied so as tobe a binary alloy of chromium and the dopant material.

In one embodiment, the at least one light element is arranged on oneside of the polymeric substrate, and wherein the polymeric substrate andthe chromium-based reflective coating are at least in part permeable tolight originating from the at least one light element.

The polymeric substrate may be used in different technical fields, suchas in automotive industry, advertising industry or any industry whichprovides products having a protective coating that does also providelight reflective as well as light transmission properties.

The chromium-based reflective coating may be based on an alloy includingchromium. Chromium is a Group 6 member of the transition metals and hasa body-centered cubic (bcc) crystal structure. Incorporated as theprimary component in the preferred binary alloy of the presentinvention, being an alloy of two principal metallic components, chromiumis used primarily for its contribution towards producing a shiny, hardsurface that is resistant to corrosion, thus bringing to the alloy thedesirable property of optical reflectivity, preferably with an R %greater than 50% so as to find acceptable use in forming a mirror. Ithas a high melting point, a stable crystalline structure and moderatethermal expansion, making it an ideal primary component for use in theharsh environmental conditions described above.

The secondary component of the preferred binary alloy is the dopantmaterial mentioned above, the dopant material herein often beingreferred to as M and being selected from the hexagonally close-packed(hcp) transition metals. The hcp structure is the most common among thetransition metals, including the transition metals zirconium (Zr),titanium (Ti), cobalt (Co), hafnium (Hf), rubidium (Ru), yttrium (Y),and osmium (Os). In this respect, some of these hcp transition metals,such as Zr, Ti and Co are practically easier materials to work with andso will be preferred dopant materials for the purposes of the presentinvention.

While it is envisaged that Zr will be the most preferred hcp dopantmaterial, and thus the present invention will be described herein mainlywith reference to Zr as the hcp dopant material, this should not beregarded as a limitation on the scope of the present invention.

In a preferred form of the present invention, the alloy will be a binaryalloy and the atomic percentage of the dopant material in the binaryalloy will be in the range of from about 1.9 at. % to about 5.8 at. %.However, within this broad range, there may be narrower ranges thatrelate to specific dopant materials, as will be described further below.

It has been found that the introduction of small amounts of a hcp dopantmaterial to the chromium (a bcc transition metal) can yield a range ofalloy compositions having an intermetallic crystal structure that hasbcc and omega-hcp phases coexisting, which has been found to providethose alloys with further advantageous properties (beyond those ofchromium alone). Indeed, it has been found that the careful selection ofthe amount of hcp dopant material relative to the amount of chromium cangive rise to alloy compositions within those ranges that areparticularly preferred, where desirable properties (such as abrasionresistance) are maximized and undesirable properties (such as a colorother than a neutral color) are minimized.

By way of explanation, it has been found that coatings according to thepresent invention change in phase composition as the elementalcomposition of the dopant material is increased, from bcc only, to bccplus omega-hcp, to bcc plus an amorphous phase. The optical andmechanical properties observed for the coatings show variationcommensurate with these changes in composition, with the preferredoptical and mechanical properties occurring when the phase compositionis bcc plus omega-hcp. Without wishing to be bound by theory, it isbelieved that the observed changes are due to the changing electronstructure of the atoms and the crystallographic conformation relative toeach other.

Specifically, when the phase composition was bcc plus omega-hcp, thecrystal structure of the coatings demonstrated d-orbital transitionswhich gave rise to neutral color and relatively lower reflectivity, withthe well-ordered crystal structure yielding higher relative resistanceto abrasion. By way of comparison, when the amorphous phase was present,the d-orbital transitions were no longer observed, indicating that theorbital hybridization between neighbouring atoms was partially fillingthe d-orbitals, correlating with a less-preferred lower reflectivity.Furthermore, the lower atomic packing density in such an amorphous phasewas found to yield coatings with reduced resistance to abrasion, whichof course is also less desirable.

With this in mind, and referring to the dopant material as M in thegeneral formula CrM_(x), this transition of phase from bcc plusomega-hcp, to bcc plus an amorphous phase, was found to occur at valuesof x of about 0.06, correlating to about 5.8 at. %, when the dopantmaterial was Zr. The same transition is expected to occur at about thesame value of x also for Ti and Co.

Unlike the reflectivity, the color of the coatings of the presentinvention was found to not show a change in trend at the transition ofthe phase from bcc plus omega-hcp, to bcc plus an amorphous phase. Tothe contrary, at the transition of the phase from bcc to bcc plusomega-hcp, which was found to occur for Zr at values of x (in the abovegeneral formula) of about 0.05 (correlating to a lower limit of about4.5 at. %), a transition in the color of the coatings of the presentinvention was found. This suggests the onset of the orbitalhybridization in the electron structure occurs at concentrations of Zras the dopant material close to about 4.5 at. %. However, the sametransition point for Co as the dopant material was found to be about 1.9at. %.

By way of explanation, and again using Zr as the exemplary hcp dopantmaterial, at low concentrations there is an increase in the resistanceto abrasion upon increasing the elemental composition of Zr. A maximumin the resistance to abrasion is observed at the transition from bcc tothe bcc plus omega-hcp, after which increasing the Zr concentrationleads to a steady decrease in the measured abrasion ratio. Indeed, froman electron diffraction analysis of CrZr_(x) coatings, two transitionconcentrations are defined that represent the change from one phasecomposition to another. For Zr as the dopant material, these transitionsare at about x=0.05 (bcc to bcc+Ω-hcp) and about 0.06 (bcc+Ω-hcp tobcc+amorphous). In this respect, the omega-hcp phase is understood to bea displacive phase transformation from the bcc structure.

Accordingly, in one example, the alloy will be a binary alloy and thedopant material will be Zr, wherein the atomic percentage of the dopantmaterial in the binary alloy will be in the range of from about 4.5 at.% to about 5.8 at. %.

In yet another form, the alloy will be a binary alloy and the dopantmaterial will be Co, wherein the atomic percentage of the dopantmaterial in the binary alloy will be in the range of from about 1.9 at.% to about 5.7 at. %. In relation to predictive conclusions able to bedrawn by the inventors (based on the similarity in the physical natureof all hcp transition metals) from the experimental work (describedbelow) conducted in relation to Zr and Co, and to an extent Ti, it willbe appreciated by a skilled addressee that the behaviour of the otherhcp transition metals as the dopant material in the present inventioncan be reasonably expected to be the same or similar to that as seenwith Zr, Co and Ti. Indeed, the comparative experimental work conducted(again, see below) on the bcc transition metal molybdenum (Mo), wheresimilar behavior was not expected (and was not seen) due to thedifferent physical nature of this transition metal, also tends toconfirm these predictive conclusions about the hcp transition metals.

Indeed, given that the physical nature of the other hcp transitionmetals is similar to both Zr and Co, it is expected that Ti, Hf, Ru, Yand Os will display the same structure forming abilities in the Cr basedalloy of the present invention when their concentration is within therange of about 1.9 at. % to about 5.8 at. %.

The coatings may preferably be ultrathin coatings, wherein the thicknessis selected to achieve the desired optical property, such astransmission and/or reflectivity. For example, the coating is beingdefined in this specification to be a coating with a thickness of 200 nmor less. In one embodiment, the coating has a thickness of 100 nm. It isenvisaged that preferred thicknesses will be in the range of 100 nm orless, or more preferably in the range of 40 nm to 80 nm, or morepreferably in the narrower range of 50 nm to 70 nm. Ideally, thethickness will be about 60 nm.

Preferably, the inventive polymeric substrate is formed by injectioncompression moulding, although any other method known in the art, suchas compression moulding, blow moulding, reaction moulding and sheetcasting, could also be utilised and thus also falls within the scope ofthe present invention.

The polymeric substrate may be any known type of polymeric substratematerial and for example could be a substrate formed from a materialselected from the group including polyacrylate, polyester, polystyrene,polyethylene, polypropylene, polyamides, polyamides, polycarbonate,epoxy, phenolic, acrylonitrile-butadiene-styrene,acrylonitrile-styrene-arylates, acetal and blends of these. Preferredsubstrate materials include polycarbonate, poly(2,2′-dihydroxyphenylpropane) carbonate, polydiethyleneglycol bis(allylcarbonate), polymethylmethacrylate and polystyrene, or blends thereof.

The polymeric substrate or the backing plate bearing the coating of thepresent invention may also include other coatings (pre-coatings) eitherbetween the coating and the substrate, within the coating, or as anouter layer. In particular, it is envisaged that in some embodiments itwill be advantageous to include a hardcoating between the coating andthe substrate or as an outer coating. In this form, the hardcoating is aprotective layer which does not contribute to the overall desiredoptical effect, while in other embodiments an external protective layerupon the decorative coating will itself be a hard coating.

In this respect, a coating that is said to be a “hard coating” is acoating that is harder and stiffer than the substrate, whereby itincreases the abrasion resistance of that substrate. Examples for hardcoats are, but not limited to, organo-silicon, an acrylic, a urethane, amelamine or an amorphous SiO_(x)C_(y)H_(z). Such an abrasion resistanthard coating is one that reduces damage due to impacts and scratching.Abrasion resistance can be measured through tests such as ASTM F735“Standard Test Method for Abrasion Resistance of Transparent Plasticsand Coatings Using the Oscillating Sand Method”, ASTM 04060 “StandardTest Method for Abrasion Resistance of Organic Coatings”, by the TaberAbrader, or by using the well-known Steelwool Test.

The abrasion resistant layers are preferably formed from one or morematerials selected from the group consisting of an organo-silicon, anacrylic, a urethane, a melamine or an amorphous SiO_(x)C_(y)H_(z). Mostpreferably, the abrasion resistant layer is an organo-silicon layer, dueto its superior abrasion resistance and compatibility with physicalvapor deposited films. For example, an abrasion resistant layerincluding an organo-silicon polymer can be formed by forming a layer ofa compound selected from the following compounds by a method such as dipcoating or the like and then curing the layer: trialkoxysilanes ortriacyloxysilanes such as methyltrimethoxysilane, methyltriethoxysilane,methyltrimethoxyethoxysilane, methyltriacetoxysilane,methyltripropoxysilane, methyltributoxysilane, ethyltrimethoxysilane,ethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane,vinyltracetoxysilane, vinyltrimethoxyethoxysilane,phenyltrimethoxysilane, phenyltriethoxysilane, phenyltriacetoxysilane,gamma-chloropropyltrimethoxysilane, gamma-chloropropyltriethoxysilane,gamma-chloropropyltripropoxysilane,3,3,3-trifluoropropyltrimethoxysilanegamma-glycidoxypropyltrimethoxysilane,gammaglycidoxypropyltriethoxysilane,gamma-(beta-glycidoxyethoxy)propyltrimethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltriethoxysilane,gamma-methacryloxypropyltrimethyoxysilane,gamma-aminopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane,gammameraptopropyltrimethoxysilane, gamma-mercaptopropyltriethoxysilane,Nbeta(aminoethyl)-gamma-aminopropyltrimethoxysilane,betacyanoethyltriethoxysilane and the like; as well as dialkoxysilanesor diacyloxysilanes such as dimethyldimethoxysilane,phenylmethyldimethoxysilane, dimethyldiethoxysilane,phenylmethyldiethoxysilane, gammaglycidoxypropylmethyldimethoxysilane,gamma-glycidoxypropylmethyldiethoxysilane,gamma-glycidoxypropylphenyldimethoxysilane,gammaglycidoxypropylphenyldiethoxysilane,gamma-chloropropylmethyldimethoxysilane,gamma-chloropropylmethyldiethoxysilane, dimethyldiacetoxysilane,gammamethacryloxypropylmethyldimethoxysilane,gammametacryloxypropylmethyldiethoxysilane,gammamercaptopropylmethyldimethoxysilane,gamma-mercaptopropylmethyldiethoxysilane,gamma-aminopropylmethyldimethoxysilane,gammaaminopropylmethyldiethoxysilane, methylvinyldimethoxysilane,methylvinyldiethoxysilane and the like.

The pre-coated films may also include, inorganic oxides (silica,titania, alumina), thin metal films (Cr, etc), where the pre-coatedsubstrate has been prepared to have the desirable surface energy,residual stress, thermal coefficient of expansion, conductivity,chemical functionality, etc, as required by the specific application ofsuch a Cr based alloy coating.

In a similar manner, a skilled addressee will understand that anovercoating may be applied over the coating of the present invention,which overcoating could include transparent coatings for the purposes ofmechanical strength, wettability, optical interference filters, modifiedcoefficient of friction, etc. The overcoating may be the abovehardcoating or any other protective layer. Such protective layer(s)provide enhanced abrasion resistance, fingerprint resistance and ‘easyclean’ functionality. Suitable materials for such a protective layercould be plasma polymerised hexamethyldisiloxane (HMDSO), fluoro polymerbased coatings deposited via evaporation or liquid transfer techniques,or a liquid hardcoat applied via spin, dip, spray or flow coatingtechniques, with or without particulate additives for haze control (mattadditive). In one embodiment, in case the polymeric substrate is used asa housing of a rear view device, the overcoating is permeable to lightfrom the light element and may have the same color as the rest of therear view device and the vehicle. In one embodiment the color may bedifferent to the rest of the vehicle.

In a preferred form, the physical vapor deposition techniques adopted inthe method of the present invention will be based upon magnetronsputtering, be it from a primary alloy target or using a co-sputteringprocess involving two targets made from the respective components of thealloy. Alternatively, it will be appreciated that the preferred alloycould be deposited using thermal evaporation or e-beam evaporation ofthe respective alloy components.

It should be appreciated that, due to the nature of polymericsubstrates, conventional temperature processing (during or afterdeposition) could generally not be employed to modify the properties ofalloy coatings of the type of the present invention, although thisfinally depends on the polymeric material of the polymeric substrate. Inthe inventive coatings, the inventors have determined that the preferredalloys change in phase composition as the elemental composition of adopant material (such as Zr, Ti or Co) is increased; from bcc only, tobcc plus hcp, to bcc plus an amorphous phase. The optical and mechanicalproperties for these preferred alloys (as ultrathin coatings) showvariation commensurate with the composition and observed changes relateto the changing electron structure of the atoms and the crystallographicconformation relative to each other.

Indeed, these crystalline ultrathin coatings demonstrate d-orbitaltransitions that give rise to neutral color and relatively lowerreflectivity, with a well-ordered crystal structure yielding higherrelative resistance to abrasion. When amorphous material is present inthe coatings, the d-orbital transitions are no longer observed,indicating the partial filling of the d-orbitals. It is believed thatthe orbital hybridization between neighbouring atoms partially fills thed-orbitals, correlating with a yellow color and higher reflectivity.Furthermore, the lower atomic packing density in the amorphous phaseyielded coatings with reduced resistance to abrasion.

It should be appreciated that many different coating compounds aredescribed throughout the present description and that the presentinvention is not limited to such coatings. For example, a coated backingplate in accordance with the present description may be coated by anytype of reflective coating not limited to the coatings described herein.

REFERENCE SIGN LIST

-   100 rearview device-   110 housing-   115 painted part-   120 rearview element-   130 bezel-   130A, 130B, 130C, 130D different positions or zones-   140 LED light strip-   150 diffuser-   200 lighting assembly-   210 connector-   220 PCB board-   230 LED-   240 lenses-   250 filter-   260 external housing-   600 flexible circuit-   610 lighting elements-   610 a first light-   610 b second light-   610 c third light-   610 d forth light-   610 e fifth light-   620 connector controlling unit-   630 flexible heater pad or ribbon circuit-   700 rearview device-   710 connector-   720 bezel-   740 receiving portion-   750 glass reflector-   800 flexible circuit-   810 lighting elements-   820 electrical connector-   830 heater pad-   840 temperature sensor-   850 communication module-   900 rearview device-   910 connector-   920 bezel-   940 light receiving portion-   950 glass reflector

What is claimed is:
 1. A multi-function rearview device for use with avehicle, comprising: a housing configured to be attached to the vehicleand to be moveable relative to the vehicle; a rearview elementcomprising a reflective element, a camera and a display element; a bezelformed at an outer portion of the multi-function rearview devicesurrounding the rearview element, with the rearview element beingattached to at least one of the bezel and the housing; one or more lightassemblies providing at least one or more light function indications atleast one sensor, wherein the bezel is made of a plastic substrate whichis transparent and coated, an interior space is formed within the bezel,and one of more light assemblies and one or more electronic means arepositioned at least partly within the interior space of the bezel, andwherein the at least one or more light function indications comprises aHuman Machine Interface (HMI), and the output of the sensor controls atleast one or more light assemblies and the display element.
 2. Themulti-function device of claim 1, wherein a coating of the bezel is atleast one of a decorative coating, an advanced surface technologysurface coating, and a spectrally controlling system, and the bezel isformed or molded from a polymeric substrate.
 3. The multi-functiondevice of claim 2, wherein the bezel is transparent and includes achromium-based coating, making the one or more light assemblies beneaththe bezel hidden until lit, and the chromium-based coating is an alloyof chromium and a dopant material, the dopant material being selectedfrom hexagonally close-packed transition metals, and the alloy having acrystal structure of a primary body-centered cubic phase in coexistencewith a secondary omega hexagonally close-packed phase.
 4. Themulti-function device of claim 1, wherein at least one of the one ormore light assemblies each comprise at least one of: a printed circuitboard; a light emitting diode an integrated lens; self-chargingilluminating material; flexible circuit board; a bulb; and a lamp. 5.The multi-function device of claim 1, wherein the one or more lightassemblies are configured to direct a plurality of different colorlights to an entire surface of the bezel so that the entire bezel canhave one color at a time, and to provide a plurality of different colorlights to different zones of the bezel so that different zones of thebezel can have different colors at a time.
 6. The multi-function deviceof claim 1, further comprising a foot suited to be fixed to the vehicleand relative to which the housing with the bezel is moveable, the footproviding at least one spherical seat for the housing.
 7. Themulti-function device of claim 1, wherein the housing comprises an upperpart and a lower part, and the bezel is attached to both parts.
 8. Themulti-function device of claim 1, wherein the bezel is attached togetherwith a least one of the one or more light assemblies and the electronicmeans to the housing.
 9. The multi-function device of claim 1, furthercomprising a connection to a control unit of the vehicle to control atleast one of the one or more light assemblies, the display element, or acamera controller.
 10. The multi-function device of claim 1, wherein atleast one of: the sensor is a camera, and the sensor is a light sensorfor controlling multiple light intensities or light brightness.